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Epec's Blog | Electronics Manufacturing Solutions


Custom Cable Assembly Extrusion 101 - Single to Multi-Conductor Cables

Written by Steven J Goodman
Posted on December 28, 2021 at 10:18 AM

The process of extruding metals, plastics, and other molten materials is common and necessary to produce many of the products used in the world today. Items such as drinking straws, PVC pipes, and even coat hangers also rely on extruded raw materials for processing. No different than a child’s playdough set or making homemade pasta, material is forced through an extruder die creating the long uninterrupted shape of whatever material is being made.

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Gasket Optimizing for Overmolded Custom Cable Assemblies

Written by Steven J Goodman
Posted on December 2, 2021 at 10:11 AM

Custom cable assemblies use various types of plugs, connector housings, and gasketing to mate and properly seal within a system. These connectors provide a way to mechanically attach to the other system components by means of a latch or a polarized connector body.

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Using a High Flexibility Silicone Wire and PTFE Wire Design

Written by Steven J Goodman
Posted on November 18, 2021 at 10:48 AM

There are several reasons to choose silicone or PolyTetraFluoroEthylene (PTFE) jacketed cable when designing a custom wire harness. Both jacket constructions are known for their high-temperature resilience and extreme flexibility. The main difficulty of selecting a PTFE is the fact that they can be a bit hard to come by.

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Incorporating PCBs and LEDs into an Outdoor Overmolded Cable Design

Written by Steven J Goodman
Posted on October 4, 2021 at 10:03 AM

Outdoor cables are used in commercial, industrial, and residential applications where they are exposed to a variety of adverse conditions. To survive a lifetime’s worth of abuse, outdoor-rated cables must be designed to stand up to the elements, rough handling, excessive moisture, extreme temperatures, and contaminants like sand or dust. Having an overmold in the design of the cable assembly, the cable terminations can be sealed and ruggedized allowing for several design risks associated with outdoor use to be addressed in an economical fashion.

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Guidelines for Designing Low-Cost Multiconductor Cable Assemblies

Written by Steven J Goodman
Posted on August 11, 2021 at 11:09 AM

Cable assemblies are needed across various industries and are utilized in goods that include consumer electronics, industrial products, mil areo, and even medical devices. Low cost does not mean low quality; in fact, low-cost cables are qualified for use on many high-reliability applications.

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Prototypes to Production: Can Your Cable Assembly Supplier Keep Pace?

Written by Steven J Goodman
Posted on June 22, 2021 at 9:10 AM

Emerging from the COVID-19 pandemic has been especially challenging for many electronics manufacturers. As the world’s production flood gates opened, deliveries that were on hold for the past year are now being asked to be rushed and pulled ahead.

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When to Use a Floating Shield on Your Mil-Aero Cable Assembly

Written by Steven J Goodman
Posted on April 13, 2021 at 10:30 AM

Shielded cables are ubiquitous across nearly all industries. Not to be confused with armored shielding, which is designed to physically protect a cable, shielded cables are used to safeguard against electromagnetic energy and the negative consequences from signal corruption, blown components, or even a failed qualification test. Cable designers will specify whether a shield is required and its general construction. But just adding a shield to a cable may not be enough to achieve the required performance levels that are anticipated.

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High Flexibility Wires for Minimum Bend Radius Requirements

Written by Steven J Goodman
Posted on February 11, 2021 at 9:15 AM

One of the most common reasons for selecting a custom cable assembly is to satisfy some type of flexibility or bending requirement. Even the bulkiest of electrical cables have some sort of give to them, allowing them to form around corners or be coiled.

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10993 Biocompatibility for Cable Assemblies

Written by Steven J Goodman
Posted on December 17, 2020 at 10:15 AM

Cable assemblies used in the medical the industries have to be biocompatible, made of a material that will not cause issues or adverse effects when coming in contact with the body. The material should not cause any type of toxicity (whether it is to the skin or to internal organs, bone, blood, or tissues) that could endanger a person's health.

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5 Custom Cable Overmold Designs with No Tooling Expense

Written by Steven J Goodman
Posted on December 10, 2020 at 9:14 AM

Overmolded cable assemblies are widely known for their superior performance, attractive cosmetics, and the fact that they can be customized for nearly any application. But overmolded cables also require a sizable investment in hard tooling well before the first cables are ever produced.

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