Tips for Designing a Custom Cable That Meets Your Requirements
When off-the-shelf components don’t meet your project requirements, a custom cable is the only solution.cable custom But designing a cable that perfectly fits your needs takes more than just listing the things you want, and it’s important to get it right because it impacts everything from cost to production timelines. To avoid the pitfalls that can lead to costly mistakes, follow these tips for making a cable design that perfectly fits your project’s requirements.
Start with a thorough requirements gathering session.cable custom This will help you identify the critical performance criteria that will drive your design decisions. This will also prevent you from specifying high-performance components that exceed your requirements – which can increase costs and handicap manufacturing efficiency.
A good partner will understand the industry standards you must adhere to – like UL, ANSI, OSHA, RoHS, Prop 65 – and be willing to work with you to make sure your design meets those guidelines.cable custom They should also be able to provide a complete spectrum of customization options, from conducting materials and strand configurations to insulation and jacketing. They should also be capable of supporting both prototype and volume production, so they can meet your specific needs in the most cost-effective way possible.
Conductor material selection is one of the most crucial decisions when designing a custom cable.cable custom Bare copper is the most common, offering a pure signal over long distances and great flexibility. However, it is not ideal for environments that require corrosion resistance. In those cases, tinned copper is a better choice, as it’s easier to solder and can withstand temperatures up to 150 degrees Celsius.
Depending on the environment your cable will be operating in, it may need to be flexible or rigid.cable custom This will influence the stranding configuration chosen. A higher strand count tends to be more flexible, while lower strand counts offer greater rigidity.
Shielding is another customizable option that can be achieved through a number of different methods including braided, spiral, foil or combinations to balance electrical shielding effectiveness with mechanical or diameter requirements.cable custom For example, a combination of four shielded pairs of 18 gauge wires, a tinned copper braid and an overall foil shield would be an effective solution for many applications.
Your custom cable will need to be able to handle the voltage rating, ampacity and capacitance required by your end application.cable custom These parameters are generally established during the requirements gathering process and will dictate the conductor size, stranding configuration, insulation type and jacket thickness you need to achieve your application goals.
Your cable assembly will likely be subject to a wide variety of environmental conditions, from humidity and heat to chemical exposure. These conditions can impact the lifespan of your cables and connectors, so it’s important to choose the materials that can withstand those challenges. A customized cable can be engineered to withstand these conditions, protecting your connections and keeping your system up and running.
Tags:aviation cable c type | cable for spiral keyboard | aviation cable type c | spiral cable usb c keyboard