custom cables

Custom Cable Form and Design Considerations

Custom cable is often the solution when mil-spec wire and cable specifications don’t work to meet your needs. Scenarios such as:

  • Improving an existing aerospace or defense application
  • Looking for a hard to find product or one that might not even exist
  • Your current cable just isn’t meeting your expectations

Custom cable is only as good as its design. As such, we kindly ask you to complete the form below to get us started on your design. Once we have all your information, we can create a custom cable that will meet your needs, and in many cases exceed them. Please complete the form as thoroughly and accurately as possible.

On this form, not only are we trying to capture the application that the custom cable is used for, but we also would like to gain an understanding of the environment in which the cable will be placed. Please put all of this information on the “Application of Cable” section. It is critically important for us to know if we are working in an engine compartment, swamp area or in an area where electro-magnetic interference may come into play.

The installation routing is another element to pay attention to so we can ensure the cable will have the correct bend radius. If your custom cable is being placed in a dynamic, moving section of the application, you may consider requesting a coil cord, which will expand and contract based on the movements of your unit.

We have also found that considering future MRO activities may impact the length of the installed custom cable. This means it may be beneficial to design in extra length to serve as a service loop which could simplify future repairs and upgrades. Of course, the extra weight of the cable would need to be measured against future cost savings, but it remains an important design-phase consideration.

Another important consideration is the connectors, backshells and strain reliefs to be placed on the ends of your custom cable. If you already have a preference, be sure to share those with us. With this information, we can select materials and create dimensions which will successfully mate with your chosen connectors. If you haven’t yet chosen connectors, we will be happy to assist in that area. This follows the concept of “starting with the end in mind”, and allows us, through proper design techniques, to avoid having a custom connector made as well.

Circuit identification is another important aspect of the design. The inner conductors of the cable can be any combination of laser marked wires and cables or inner conductors comprised of different colors or stripe combinations. You can also mix laser marked conductors with solids or stripes, based on your identification preferences and guidelines. The outer jacket can come in many colors and can be printed with the function, part number, applicable specification or anything else you specify.

Once your cable design is completed, a WireMasters WM9100 series part number is assigned to the cable, allowing for easy quoting and ordering in the future. Furthermore, we can work with you to keep a supply of inventory readily available, avoiding lengthy lead times and minimum order quantity requirements. The Vendor Managed Inventory Solutions section describes that service more completely.

Beyond what is written above, there are even more attributes to consider – such as shielding, testing requirements and more. Your WireMasters Account Executive can walk you through all the details, making sure we “check every box”!