Custom-made and bespoke cables manufactured to client specification. Any conductor configuration, insulation, shielding, sheath, and jacket material. For special-purpose industrial, marine, subsea, and aerospace applications.
When no standard product meets the application requirements, we design and manufacture custom cables to client specification. Our engineering team works from client-supplied specifications — or develops the specification in consultation with the customer based on the application environment, mechanical duties, electrical requirements, and relevant standards — to produce a cable that is precisely matched to the application rather than adapted from a standard product.
Custom cables are manufactured for quantities from small prototype runs to full production volumes, with full traceability documentation, test certificates, and factory acceptance test records available for each production lot. Lead times and minimum order quantities depend on the specification complexity and material lead times.
| Document | Available |
|---|---|
| Test certificate (per drum) | Yes — standard |
| Factory acceptance test report | Yes — on request |
| Material traceability | Yes — raw material certs |
| Third-party type test | Yes — on request |
| RoHS / REACH declaration | Yes |
| Country of origin certificate | Yes |
We work with your engineering team to translate application requirements into a cable specification — identifying the critical parameters (voltage, current, temperature, mechanical duty, environmental exposure) and selecting materials that satisfy all requirements with appropriate margins.
For critical applications, we produce a prototype run for customer evaluation and testing before committing to full production tooling. This process identifies any application-specific issues before they become production problems.
Production cables are manufactured with full quality control and test records. Electrical tests (insulation resistance, conductor continuity, voltage withstand) are performed on every production drum, with results recorded on the drum certificate.
The perception of a custom cable means many things to different people.
It could simply mean that an alternative jacket material or possibly that a different colour or conductor colours are required.
It could also mean that you have a requirement for a highly complex solution where a cable with very specific materials and configurations are required.
We want to dispel the myth that a custom cable generally equals high cost and long delivery dates. Whether your looking for a simple material alternative,
alternative core colours to an existing cable type or require a complete design from first principles then we have a solution for you.
These products can be designed either from first principles or using existing off the shelf products allowing you to select varying material configurations alongside solid technical advice.
You can determine the appropriate level of screening that is required on either individual elements or around the cable as a whole.
You can also specify the outer jacket working environment and select a material type that is appropriate both from an operating temperature and mechanical characteristics point of view.
We are here to advise on what options are available to you which makes the process as easy, efficient and cost effective as possible.
Custom Cable Examples:
This custom cable features
15 conductors of 24 gauge overall shielded and jacketed,
6 shielded pairs of 24 gauge with an overall jacket,
4 conductors of 18 gauge shielded and jacketed,
4 individually jacketed twisted pairs of 18 gauge,
6 single conductors of 24 gauge,
4 RG 58A/U coaxial cables and 2 vent tubes
all under an overall red polyurethane jacket.
and an outer core of 15 pairs of PTFE insulated 26 gauge silver platted copper.
There is an 85% tinned copper braid with an overall black PVC jacket.
The next pass is made up of 10 shielded pairs of 16 gauge,
and the outer pass consists of 16 shielded pairs of 16 gauge.
There is an overall foil shield, all under a black PVC jacket.
