Why CAI is the Answer for All Your Custom Electrical Component Needs When you need to outsource the manufacturing of custom wire harnesses, cable assemblies, or other electrical components for your project and want someone who can handle it all — from design to...
As the Protective Outer Layer, the Jacket is an Essential Part of the Electrical Cable Similar to the coats and jackets we wear on cold winter days, the main reason for the jackets, or sheaths, on electrical cables is protection. While a cable jacket also...
For Best Results From Your Cable Assemblies, It Helps to Know What Not to Do In the world of cable assembly manufacturing, precision and adherence to best practices during every step are essential to ensuring safety, reliability, and optimal performance....
To Realize Their Benefits, Wire Harnesses Must Be Be Optimally Sized Designed to transmit signals and power smoothly within an electrical system, wire harnesses are the organized bundles of wires, cables, and connectors used in a wide variety of electrical...
CAI Overmolds Off-the-Shelf Solutions for Optimal Cable Strain Relief Traversing long distances and used in a variety of demanding environments to transport power and data to and from electrical devices, electrical cables and cable assemblies must be built to...
Building a high-quality, highly reliable electrical component such as a cable assembly takes expert craftsmanship, the right tools, and quality materials. However, having the right specifications and design from which to start is equally important.
When a company seeks to outsource that work to an Original Equipment Manufacturer like CAI, it typically starts with a quoting process in which the requesting company provides information and data for CAI to begin the design review phase and work to assure the final product meets the intended application/specifications.
While you may not have everything quite figured out yet or may need some expert help choosing the best solutions, the more details you can provide during the quote stage, the quicker and more accurate the quote will be, which will lead to a more satisfying overall experience. Regardless of where you might be in the process or your level of experience, CAI embraces creativity and can work with everything from a napkin sketch to a 3D rendering. Connect with us or request a fast, accurate quote today!
Getting a firm grasp of the cable assembly’s intended application and what you are expecting is key to CAI providing an optimal solution and more seamless process.
One of the most important ways to get an accurate quote is by providing a detailed two-dimensional drawing or 3D CAD file for 3D printing. Cable assembly drawings typically include a lot of the information the manufacturer will need. If you have no drawing, here is the basic information you’ll need to provide so that a preliminary design/drawing can be made:
At the center of each electrical wire, and each individual wire within a cable, is a conductor which is the electrical highway for carrying power or data from one point to another. Conductors are typically made of metals due to their ability to effectively conduct electricity. However, different metals feature different properties and conductivity levels, and certain coatings can even be applied to enhance performance. This gives manufacturers a variety of options when crafting an electrical system to perform optimally in its intended application and environment.
The cable jacket is a typically thermoplastic or thermoset outermost layer that acts as the critical protection between the conductor and the environment. The jacket material affects temperature rating, flexibility, and overall resistance to moisture, chemicals, and other threats.
Cable shielding is protective conductive sheathing wrapped around jacketed wires to act as a barrier between the conductor and outside interference. Shielding protects the internal signal and the outside environment from each other.
A cable’s connector is a metal and plastic interconnect that allows the wire’s internal copper conductor to be properly mated with the other parts of the assembly. Connectors range in cost and complexity, so it’s best to properly match the application with your connector scheme. Many connectors have less expensive equivalent/sub options.
Aimed at enhancing the durability and/or customization of your cable assembly, custom overmolding uses specialized injection-molding machines to mold plastic or rubber over cable assemblies and their connectors. The overmolded cable assemblies created at CAI can be customized with colors, logos, and safety information and protect your harnesses from heat, friction, moisture, abrasion, compression, and more.
Depending on a cable assembly’s intended use and future environmental conditions, there are many mechanical, environmental, and electrical testing procedures used to measure performance, durability, and safety.
CAI 100% tests all final assembly parts to specification. Tests can be performed on each cable produced or on an acceptance quality limit (AQL) sample size. Many tests require specialty fixtures, testing equipment, and the know-how to use them in order to diagnose and troubleshoot. While most cable assembly testing is applied in the final stage of the manufacturing process, some testing is done in development (i.e., strain testing), and some tests need to be performed in-process to demonstrate that a step was completed.
Again, no need to worry if you don’t have every little detail decided when seeking a quote. By supplying the most important information, you’ll give your OEM a good head start on your project, and CAI is ready to roll up our sleeves and get you to production!
If you’re not exactly sure of where to start, the experts here at CAI can guide you toward the best materials, specs, and design for your project. For over 35 years, we’ve provided custom cable assembly, wire harness, and other electrical component solutions to companies big and small in just about every industry. Request a quote or start a conversation with us today!