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Atif Mallo

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10 important facts you need to know about custom cables


Custom Cable means cables designed or engineered out of existing or standard cables to perform a specific function or multiple functions, simultaneously. Since these cables are versatile in usage, Custom cables are not only slightly on the higher side in terms of price but the convenience of custom-built cables make up for the high costs, quite easily.

10 important facts you need to know about custom cables

High quality custom cables perform more than one function. The market for custom cables is expanding ever since human beings decided to do away with the mess of cables spread all over the place particularly after the advent of technology. Custom cables are useful in IT, Entertainment, radio Channels, Music production companies, theater, concert venues, construction and across the spectrum of manufacturing industries.

Custom cable designing gives the designer ample room to exercise control over selecting his/her own number of conductors, color codes, resistance, insulation, jacketing and AWG sizes. In addition, custom cables have the convenience of fitting perfectly into relevant components including connectors, grips, sockets etc. by maintaining the requisite diameter sizing.

Different Types of Custom Cables

Custom cables cannot be classified however the most common types of custom cables are as below:

• Multicore Cables

• Low voltage power cables

• High voltage power cables

Multicore Cables are the most common type of custom cable. Multicore cable has more cores to it than the cable of that specific type will have in the standard product. Multicore cable is engineered and built by bundling together different cores with a single cable to make it perform more than one function at the same time, for better output. Thus, multicore cable has the convenience of performing multiple functions such as power, data transfer and even AV elements in one cable. The split ends are split ends need multiple conductors and connectors wherein Fischer Connector Distributor enhances the results to the maximum.

Since multicore cables are built by twisting together different cores to form one cable with multiple connectors, best being Fischer Connector Distributor of different sizes, heavy jacketing is required for protecting the cable from damage and to minimize the instance of electromagnetic interference.

Uses of multicore cables include electronic equipment, aircrafts, medical equipment, concert venues, and theatres.

Low Voltage Power Cables are used to supply data and electrical power. The most common usage of this kind of transmission is USB, that small device which has taken the world by storm. USB is for data transfer, power supply and to connect various component of the computer to the CPU in a standard PC. Some USBs with heavy data storage come with two connectors for data and power each to ensure smooth transfer of data. Due to its functionality USB is a component of smartphones now.

High Voltage Power assembly with a capacity of 120 volts or more comes with electrical conductors generally placed together. Typically, we have two types of uses for power cables i.e. wiring within buildings and power supply cords attached to electric appliances.

10 Important facts

Custom cables, with their dynamism and versatility of use, offer immense room for innovation for builders and engineers of these wonderful products. However, there are certain points to be kept under consideration while building these cables for greater user experience.

Professional help is required when you plan to design or build a custom cable. There are DIY websites and tutorials available on the internet, however, never ever totally rely on these materials as the process is expensive plus the applications you want to use the cables with are even more expensive. So, exercise discretion.

Quality of material is the key to building top-quality and high-performance custom cables. Never compromise on the quality of the raw material because that will affect the performance of the cable.

Conductors and Connectors are the main components of custom cables. Between 30 AWG to 4/0, conductors are available in a range of sizes to accommodate the possibility of using up to 85 conductors, choosing from a variety of coppers including bare, tinned and silver-coated copper (used for high-temperature cables). If you want to play it safe, you can rely on Fischer Connector Distributor.

Insulation is the crux of the custom cable building process. It minimizes damage and minimizes the incidence of electromagnetic interference. Depending on the need you may choose from a variety of insulators including polyvinylchloride (PVC), Fluorinated ethylene-propylene (FEP), Polyethylene (PE), polypropylene (PP) and thermoplastic elastomer (TPE).

Cabling involves organizing the conductors within the cable which process comes with a number of options including pairing, grouping and even grouped conductors with individual shields.

Shielding is the most important aspect of building a custom cable. A range of shielding options are available including foil shielding, spiral shielding, and braid shielding, independently or in a combination of all three. Braid and spiral are effective against low-frequency electromagnetic interference (EMI) interference whereas foil shielding gives reliable protection against high-frequency electromagnetic interference (EMI).

Jacketing is crucial for achieving the desired results from a custom cable. There are a number of jacketing options to choose from including polyvinylchloride (PVC), Polyethylene (PE), fluorinated ethylene-propylene (FEP) and thermoplastic elastomer (TPE).

Regulatory Approvals need to be paid attention while building a custom cable. Selecting one type of materials may have repercussions for ruling out other materials and the same holds the ground with regard to one set of products against another. So, you need to be very careful. The approvals required may include some in the nature of environmental, laboratories and product standards.

Voltage ranges need to be adhered to while working on custom cables. Normally, on multi-conductor voltage ratings range are 300V, 600V, or 1000V, with occasional 30V, 150V or 250V. For greater convenience, you can use the Fischer Connector Distributor.

Temperature ranges need to be kept in mind while designing and building custom cables. Normally the ranges are for high temperature 75oC, 80oC, 90oC, 105oC, 125oC, 150oC, and 200oC. For the low temperature range the standards are -80oC, -40oC, -20oC, -10oC, and -5oC.

Custom Cables generally win positive reviews from customers. From simple IT equipment to military tough cabling for flawless surveillance using multiple conductors, pairings and coax composite, custom cables do serve their purpose no matter how complicated it is.

Custom cables if properly built are energy-efficient usage. It’s the versatility and flexible functionality of custom cables which make this wonderful product a favorite for individuals and groups for using with the simplest to the most complex equipment and processes.