Benefits of Custom Cable Assemblies in Manufacturing

Understanding Custom Cable Assemblies

Because standard cable assemblies have limitations, organizations often require more tailored manufacturing cable solutions.   

What are Custom Cable Assemblies?

Custom cable assemblies are specifically built to meet the unique requirements of a given application or use case. Whereas, standard/off-the-shelf/generic cable assemblies exist to serve a wide variety of applications.

These assemblies comprise many of the same basic components, such as wires, connectors, terminals, insulation, and shielding. However, the configuration and design of these components are what sets them apart. 

Industrial 3D printing extensively uses custom cable assemblies. They connect motors, sensors, and control units within the 3D printer, so they can operate accurately and efficiently. This is only one area where you will find them.

The Role of Custom Cable Assemblies in Manufacturing

Custom cable assemblies enable innovation in manufacturing processes and product designs by offering enhanced flexibility, improved performance, space optimization, and increased reliability.

Generally, these elements are why tailored solutions give businesses a competitive edge in the market. Custom cable assemblies take innovation even further by incorporating the latest technologies, designs, and approaches. Businesses can afford themselves a competitive edge in the market by adopting them.

Due to faster network speed requirements, the global cable assembly market is expected to grow by USD 111 billion over the next decade.

A large portion of this growth will be spurred by customers seeking more tailored high-performance cable assembly solutions that only custom cable assemblies can provide.  

Key Benefits of Custom Cable Assemblies in Manufacturing

In most cases, standard industrial cable assemblies are sufficient enough to satisfy the requirements of your project or application so why use a custom one?   

Enhanced Efficiency

One of the main custom cable assembly benefits is that manufacturers can fine-tune their designs and properties. 

Manufacturers and designers can optimize the signal integrity, reduce electromagnetic interference (EMI), and improve the overall durability of the cable assembly through customization. These values are all crucial for advanced manufacturing operations and high-performance products.

Using Custom Cable Assemblies to Optimize Automotive Component Manufacturing

A notable automotive component manufacturer had been experiencing an influx of customer complaints related to faulty cable assemblies connected to their engines. The company addressed this by implementing the 8D model which largely involved re-designing and customizing their cable assemblies. This reduced defects and enhanced overall manufacturing efficiency.

Improved Reliability

The performance isn’t the only aspect that designers and manufacturers can modulate when creating custom wiring harnesses. They can also enhance the durability and reliability of cable assemblies through the design and use of robust custom materials. 

Because custom assemblies are made for specific applications, they last longer in those use cases. They’re also less likely to fail and result in unexpected equipment shutdown and downtime.         

Improved System Uptime

Some studies found that improving and implementing custom cable assemblies in automotive manufacturing could reduce downtime by as much as 30%. This led to increased productivity and cost savings.

Cost-Effectiveness

Custom cable assemblies may sometimes have high upfront costs. However, because they can reduce mechanical and electrical failures, they can be more cost-effective than their standard counterparts in the long run. 

Tailored Customization

Because of their ability to drive innovation, custom assemblies have led to the discovery and use of specialized component materials such as: 

• Wires – High-Performance Alloys and Conductive Polymers.
• Insulation Materials – Teflon (PTFE), Silicone, and Polyimide (Kapton)
• Connectors – Gold-plated connectors, Waterproof Connectors, and High-Density Connectors
• Shielding – Braided Shielding, Foil Shielding, and Combination Shielding

For example, gold-plated connectors are excellent for high-reliability applications because gold plating facilitates greater conductivity and corrosion resistance. Customized shielding such as copper or stainless-steel-based braided shields can provide enhanced protection along with mechanical protection.  

In addition to the above, manufacturers can further enhance custom cable assembly manufacturing by integrating sensors and other techniques. When combined with the latest advancements in manufacturing, they can perform predictive maintenance to prevent equipment and machine breakdowns.  

Compliance and Standards

Manufacturers can design custom cable assemblies to closely meet specific industry standards and regulations. Adhering to these standards and regulations ensures that the cable assemblies (and their systems) comply with industry-established safety and quality requirements.

Key certifications that custom assembly manufacturers must follow include: 

• ISO 9001:2015
• UL (Underwriters Laboratories) 
• IPC/WHMA-620
• RoHS (Restriction of Hazardous Substances)
• ITAR (International Traffic in Arms Regulations)
• AS9100   

WellPCB adheres to the above standards, regulations, and certifications through its strict implementation of the latest safety practices and protocols. This applies not to just its manufacturing cable solutions but to all its other fabrication and assembly services.   

Customization Options for Cable Assemblies

Custom cable assemblies can consist of a wide variety of materials. Common materials and material types used in cable assemblies include: 

Conductive Material

• Copper: A flexible material that features high electrical conductivity and corrosion resistance. It’s widely used in general wiring, power distribution, and electronics.
• Optical Fiber: Comprise a collection of miniature tubes that transfer digital signals using light. They’re immune to EMI, making them ideal for telecommunications, data transmissions, and networking applications.
• Nickel-Chromium (Nichrome): Used in applications such as heating elements, aerospace, and industrial applications because of its high-temperature performance and resistance to oxidation and corrosion.
• Copper-Nickel (CuNi): Features moderate conductive qualities but is used in marine applications, desalination plants, and heat exchanges because of its corrosion resistance.
• Aluminum: Showcases good conductivity and is lightweight. It’s found widespread use in automotive, aerospace, and power transmission applications where weight reduction is important.

Insulation Material

• Teflon (PTFE): Used in high-frequency cables because of its ability to tolerate high temperatures. It’s also chemically inert and showcases low friction.
• Silicone: A widely used flexible material with high-temperature resistance. It’s used as insulation in cable assemblies for medical equipment, motor vehicles, and industrial machinery.
• Polyimide (Kapton): Its high thermal stability and excellent electrical insulation make it ideal for insulation in cable assemblies for aerospace, electronics, and high-temperature environments.     

Shielding Materials

• Copper Braiding: Performs exceptionally in environments with high EMI such as manufacturing and military applications. This is due to its flexibility and high EMI protection.  
• Aluminum Foil: It’s lightweight and provides above-average EMI shielding, making it suitable for custom cable assemblies implemented in telecommunications and consumer electronics.  

Connectors

Because devices and systems come with a variety of ports and interfaces, custom cable assemblies need to support as many connection standards. Common connector types include:

• Plug Connectors – USB Connectors, Audio Jack Connectors, and Power Plug Connectors.
• Socket Connectors – RJ45 Connectors, D-Sub Connectors and IC Sockets
• Circular Connectors – MIL-Spec Connectors and M12 Connectors
• Coaxial Connectors – BNC Connectors and F-Type Connectors
• Fiber Optic Connectors – SC Connectors and LC Connectors
• Specialty Connectors – HDMI Connectors and SATA Connectors

Designers select these connectors based on their specific properties and applications. You can incorporate additional specialized features into customized connectors like locking mechanisms, waterproofing, and high-density pin configurations. All of this results in improved functionality and reliability.

Integrated Features

Engineers and designers can integrate special features into custom cable assemblies that aren’t typically integrated into standard ones. 

For instance, they can integrate embedded sensors to monitor key manufacturing parameters such as temperature, humidity, and pressure. Alternatively, LED indicators can be integrated into cable assemblies for visual feedback. 

Custom cable assemblies can be optimized to deliver higher data transmission speeds, making products more functional and durable. 

Trends and Advancements in Cable Assembly Technology

As more people seek reliable manufacturing wiring and high-performance cable solutions, the cable assembly industry is set to advance more rapidly.  

Latest Trends in Cable Assemblies

Some recent advancements and trends in cable assembly include:

• Optical Modulators: Ultra-high-speed optical modulators that can produce speeds 10 times faster than current devices. 
• Wavelength Division Multiplexing (WDM): Increases the capacity of optical fibers by using multiple wavelengths.
• Orthogonal Frequency Division (OFDM): Enhances data transmission rates and reliability by encoding digital data on multiple carrier frequencies.

Manufacturers have also begun to add smart cable assemblies to their arsenals. These include embedded sensors, IoT integration, and customizable and programmable assemblies. These features will result in improved and more reliable cable assembly customization which will allow manufacturers to create more stable and sustainable products.

Real-World Case Studies

Custom cable assemblies have found widespread usage in various real-world applications. 

Electronics Manufacturing

A leading manufacturer of medical devices required custom cable assemblies for their products. Because they would be used in critical medical applications, the cable assemblies had to be durable, robust, reliable, and compliant with the strict standards of the medical industry.

The Outcome

Our design team met the client’s demands using reinforced custom connectors and high-performance braided shielding. These elements helped ensure the reliability of the custom assembly and minimize potential downtime.

Heavy Machinery

A leading construction equipment manufacturer required cable systems and harnesses to connect their heavy machinery and equipment. They wanted cable assemblies that were resistant to harsh construction environments. Thus, the cables had to be robust, reliable, and durable. 

The Outcome

Our designers used cross-linked polyethylene (XLPE) for insulation because of its ability to protect against heat and mechanical shock.

We then used a combination of tinned copper and aluminum for the conductors. Tinned copper is highly resistant to corrosion and oxidation while aluminum would help lessen the weight of the cable assembly.

By leveraging these materials, we were able to meet the demands and requirements of the client. This custom cable assemblies that could function efficiently in the harsh environments of construction.

Best Practices for Custom Manufacturing Cables

Manufacturers can enhance the reliability and performance of their cable assemblies by following simple design and implementation practices. 

Design Best Practices

Designers should consider using modular design where they can.

Modular design allows manufacturers to build proprietary replacement parts for cable assemblies and standardize them, positioning them as the sole supplier of replacement components.  

Modular design allows you to easily swap out or upgrade individual components without affecting the entire assembly. Manufacturers can fabricate these modules en masse to reduce manufacturing costs. 

In addition to the above, modular design improves quality control, eases maintenance, and enhances design flexibility.  

Manufacturing Best Practices

Along with modular design, it’s crucial for manufacturers to implement stringent quality control measures throughout the cable assembly. This ensures reliability, prevents defects, ascertains compliance with standards, optimizes costs, and encourages continuous improvement.

Quality Control Protocols for Custom Cable Assemblies

Some examples of quality control measures include: 

• Incoming Material Inspection
• In-Process Inspection
• Electrical Testing
• Mechanical Testing
• Environmental Testing
• Visual Inspection
• Final Quality Audit

Documentation and Traceability

Manufacturers should also maintain detailed documentation for each batch of cable assemblies, including inspection reports, test results, and material certifications. These practices ensure traceability and accountability throughout the manufacturing process.  

Maintenance and Troubleshooting

By clearly labeling cable assemblies, manufacturers make it easier for technicians to quickly identify cables, connectors, and components. 

This makes troubleshooting easier, saves time, and makes cable assemblies safer to maintain and repair. 

Best Labeling Practices for Manufacturing Cable Solutions

When labeling cable assemblies, you should: 

• Implement durable labels
• Use clear and legible text
• Employ a consistent labeling system
• Assign unique identifiers
• Optimize the placement of labels
• Use color coding
• Include essential information
• Perform regular updates

Common Challenges in Custom Cable Assemblies and Solutions

Custom cable assemblies can come with several challenges.     

Managing Complexity in Design

Custom cable assemblies often have complex design requirements. Manufacturers can overcome these complexities by following the best practices we covered in the previous section.

Ensuring Durability and Reliability

Clients may require custom cable assemblies to withstand harsh environmental conditions. These include extreme temperatures, moisture, and chemical exposure. As was the case with our construction equipment case study, these challenges can be overcome through careful material selection and usage.

Balancing Cost with High Performance

Custom cable assemblies can be expensive to produce, especially in small quantities. Manufacturers must consider using strategies such as modular components and design for manufacturability. They can also partner with suppliers and negotiate better pricing for materials and components. 

Conclusion

The benefits of custom cable assemblies are numerous. They’re more durable, reliable, and functional than their generic or standard counterparts. This is because they’re specifically designed for their applications. By using tailored solutions like these you can improve the reliability, cost-effectiveness, and overall performance of your manufacturing operations. 

As an established manufacturer of PCBs, cable assemblies, and other components, WellPCB can testify to this. We use high-performance cable assemblies within our operations. If you’re looking for a guiding hand for your next custom cable assembly project, contact WellPCB today for personalized support.

Frequently Asked Questions (FAQ)

What are custom cable assemblies and how do they differ from standard assemblies?

Custom cable assemblies are tailored to specific requirements and applications, whereas standard assemblies are pre-manufactured with fixed specifications.

How do custom cable assemblies improve manufacturing efficiency and reliability?

They enhance manufacturing efficiency and reliability by providing precise, application-specific solutions that reduce installation and minimize the risk of errors. 

What specific benefits do custom cable assemblies offer to different types of manufacturing operations (e.g., automotive, electronics, heavy machinery)?

Manufacturers can design and build custom cable assemblies for specific types of manufacturing operations. For instance, they can provide optimized connections for vehicle electronics and environmental resistance for heavy machinery in construction.

What customization options are available (materials, shielding, connectors, etc.) and how do they enhance performance?

Some components and materials that manufacturers can potentially customize include shielding, connectors, jacket materials, and color coding. Through customization, you can improve mechanical stress resistance, shielding against EMI, enhance connectivity, and ensure the safe usage of the cable assembly.    

How do custom cable assemblies contribute to cost savings and reduced downtime in manufacturing?

Custom cable assemblies provide precise, application-specific solutions that streamline installation processes, minimize errors, and enhance overall system reliability. This reduces the necessity for constant maintenance and replacements.  

What are the latest trends and advancements in cable assembly technology for manufacturing?

Some of the most notable advancements and trends in cable assemblies include automation, robotics, 3D printing, sensors, and high-speed data transmissions.