5 Options for Custom Cable Assemblies and Connectors

Cabling and wire have a long and deep history in industry, and remain an integral part of the efficient and effective workings of our society today. That is why getting the best and most from your custom cable assemblies is paramount to making sure your design or application works the way you intended. However, there are a variety of elements that contribute to making the best custom cables in terms of quality, and many factors must be considered during the design process. Here are five options to consider to help you get started.


At the core of the cable construction process are conductor materials. The best suppliers will provide you with a host of conducting materials to choose from, in multiple configurations and gauges of wire. From bare copper wire, which has been in use since the 19th century, to tinned and silver plated copper wire for higher fidelity conductive properties, customers have a wide range of materials to choose from, so that they can pick the best conductor to meet their application’s specifications exactly.


Insulation is a critical component in wire and cable goods, and is composed of non-conductive materials that keep the conductor transmitting signals effectively and safely. A good insulator will protect the integrity of the wire’s signal against environmental concerns such as water, humidity, heat, or pressure. It can also prevent the electrical signal from leaking, which can cause reduced electrical performance. There are tons and tons of insulating materials to choose from, each with its own unique advantages. Your custom cable consultant will be able to help you choose the best one for your needs.


One of the lesser known parts of a wire or cable is the shielding. Shielding can be composed of a variety of materials, including aluminum foil, mylar,, braided or spiral served wire, and EMI or RFI shielding. The wire’s shielding is intended to protect the integrity of the cable’s signal. In general this means limiting interference, static, and other types of magnetic noise.


The most visible aspect of the custom cable is its jacket. The jacket is the final outer layer of a cable and is meant to protect the innards of the wire from water, humidity, and pressure. Many of the same materials used in shielding are also used for jacketing purposes. Often there is a tradeoff between the jacketing materials ability to protect the cable, and the cable’s flexibility.

End Connectors

Finally, given the different devices that you will be interconnecting with your custom cable, you will also be given a choice in the type of end connectors used. From coaxial connectors, to HDMI, to RGA connectors, you will be able to custom design a cable that is ideal for your needs.

To speak with a professional cabling consultant to design a custom solution to your next project, click here now!