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Cable Design Questions

We experience 80% of our cable failures in backshell design. Are there any new developments in this area?
A number of issues can cause backshell failures, such as EMI, strain relief, environmental seal, and cable
guide (90/45, etc). EMI is probably the most common issue, particularly how the cable shield transitions to
the backshell. Gore has recently developed several new designs and process solutions. Also, Gore is
addressing environmental sealing problems with moulds or by potting the inside of the backshell.
Do you have any ideas on how to reduce cable tangling?
Cable tangling occurs in applications where cables are in motion, particularly if they are in a cable chain or
the cable is just moving. Packaging is critical; individual wires should be packaged into a round cable jacket, or
at a minimum, a shrink tube or expando-sleeving should be put around the cable to hold the wires together
and manage them. If you are doing some continuous motion or repeated flexing with rest in between,
moving cables generate kinetic energy that allows the conductors and insulation to relieve the stress input
during manufacturing of the materials. And when you input kinetic energy, the wires want to eliminate the
stress. They will actually move, corkscrew, and tangle, so it's very important to manage the wires carefully so
that they don't tangle.
The most effective way is to package them into a planar cable, also called a flat cable. Planar cables are
revolutionizing the linear motion, high-flex area because they take individual round constructions and
eliminate the need to put dividers and shelves into a cable chain to keep the round constructions from
tangling. By packaging the cables into a flat construction, you now have a smaller, lighter cable, and you can
use a smaller, lighter cable chain if the stroke length is long enough to need a chain. Flat cables are the ideal
way to keep your cables from getting tangled.
My interest is to reduce the amount of testing required. Are there any tests that you can submit cables to
that prove their fitness for harsh environments, or do you have to perform application-specific tests?
If you don't want to perform application-specific testing, then you should at least make sure your
manufacturer understands the challenges of your environment and can provide sufficient data to ensure that
the cable will not be compromised. Depending on how critical cable performance is and how harsh your
environment is, you may need to work with your manufacturer to test the cable.
I have an application that uses TXL wire inside closed convoluted tubing. The wires vibrate so much that the
insulation is wearing away. Would braiding the wiring harness be a potential solution instead of closed
convoluted tubing?
If you braid the wires, the vibration will generate kinetic energy, and this will further reduce the cable's
performance. I suggest that you evaluate your total cost of ownership for this application. If vibration is truly
your biggest issue, you may want to consider a more durable wire.


Q. I don't have specifications for the cable I need. Can I send you a sample?

A. Yes, Custom Cable Assemblies can reverse engineer most cables. We are also available to assist you in a
consulting capacity if you are not sure of what product is necessary for your application.

Q. What kind of quality program do you have in place?

A. Custom Cable Assemblies uses the directives of Mil-I-45208A as a basis for our quality assurance program.
All materials are inspected upon arrival. The first step of every process is inspection. We have inspection
points built into every manufacturing procedure as the assemblies are built. Before shipping, our Quality
Assurance department does a final check for proper electrical and cosmetic details as well as adherence to
customer specifications.

Q. Does Custom Cable Assemblies sell directly to Original Equipment Manufacturer?

A. YES! We are proud to have supplied cable assemblies directly to many large and small Original Equipment
Manufacturer. Our customers include Telephonics, Aeroflex, Northrop Grumman and more.

Q. What about distributors?

A. Custom Cable Assemblies is a direct supplier to leading electronic distributors, including Richardson
Electronics, Microwave Components, Microstock and others.
Q. Why else should I consider Custom Cable Assemblies?

A. Our product offering is broad enough that we can help consolidate your approved vendor list, and our
stocking program allows customers to not only limit their inventory but also reduce product to market cycle
time and reap volume discounts that otherwise wouldn't be possible.
Q. What does Custom Cable Assemblies look for in an applicant?
QUESTION: There are many contract manufacturers in the US and abroad that make
custom cable assemblies, wiring harnesses, etc. What makes CNC-KE
special/different/better that it's competitors?
Answer:
QUESTION: Who should I ask for regarding requesting a contract manufacturing quote?
Answer:
QUESTION: Who should I ask for regarding placing a contract manufacturing order?
Answer:
QUESTION: What are your main areas of specialization?
Answer:
QUESTION: How long does it usually take to get a prototype?
Answer:
QUESTION: Can you handle rush orders? Is there an extra charge?
Answer:
QUESTION: What about guarantees - what happens if products don't meet our specs or
there is some other issue?
Answer:
QUESTION: What are your standard payment terms?
Answer:
QUESTION: Are special payment terms available?
Answer: