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The Engineer’s Guide
To Custom Cable Design
By Bridget Locke
Custom cable design can be a bit overwhelming, especially
if you are like many and left the cable and connector
design until the end of the project. There are
many different factors that can affect material selection and
many different materials to choose from! So how or where
does someone even start with designing a custom cable or
complete connectivity solution for a specific end application?
As with any project, a requirements gathering session is
imperative to designing the right solution for the needs of
your device or application. Having an understanding of the
application and the environment it has to perform in will help
the cable design engineer choose the appropriate components
and cable materials.
Requirements Gathering
Time – Temperature – Frequency – Concentration
‘Needs’ vs. ‘Nice to Haves’
Flexibility – suppleness, a measure of how much movement
a cable can tolerate at a given time
Flex life – how often the cable will need to flex
Another important aspect of the initial design consultation
will be to get an understanding of any existing pain points or
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