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Off the Shelf Cables Can’t Compete with Custom Cable Assemblies

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There are numerous scenarios when an ordinary off the shelf cable will work just fine for the desired application. Typically, off the shelf cables are designed and manufactured in common configurations, lengths, colors, connector styles, etc., that cover a plethora of customers’ needs. For example, there are thousands of different black 3-foot USB cables that are readily available and in stock through various online and brick and mortar retailers.

But what if you knew that you needed 10,000 black 3-foot USB cables? Cheaper options may exist for an order quantity of this size. Or what if you needed a black 3-foot USB with additional shielding that can withstand EMI emissions? Or instead of a black cable, you needed a navy blue overmold that matches your company’s branding and logo?

In these scenarios there is a high probability you will save time and money and get added functionality by tooling a custom cable with a full-service cable supplier like Epec Engineered Technologies.

Why settle for an off the shelf solution when you can have everything you want in a custom cable assembly? Listen to this webinar as we discuss how off the shelf cables simply can’t compete with custom cable assemblies.

For more information on our cable assembly solutions visit https://www.epectec.com/cable-assemblies/.

Publié dans : Technologie
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Off the Shelf Cables Can’t Compete with Custom Cable Assemblies

  1. 1. Manufacturing That Eliminates Risk & Improves Reliability Off the Shelf Cables Can’t Compete with Custom Cable Assemblies 02.21.2019
  2. 2. Manufacturing That Eliminates Risk & Improves Reliability 2 Agenda  When to Use an Off the Shelf Cable  Risks Using an Off the Shelf Cable  Benefits of Using Custom Cable Assemblies  How to Get Started With Your Custom Build  Summary
  3. 3. Manufacturing That Eliminates Risk & Improves Reliability 3 When to Use an Off the Shelf Cable
  4. 4. Manufacturing That Eliminates Risk & Improves Reliability 4 When to Use an Off the Shelf Cable  When your system design can support it – Length, connector configuration, etc.  Stock availability – Review distributor stock position  Demand volumes matter – 10 pcs vs 10K pcs  Where are you in the development process? – What will your device be used for? Consider using a stock off the shelf cable for proof of concept testing
  5. 5. Manufacturing That Eliminates Risk & Improves Reliability 5 Risks Using an Off the Shelf Cable
  6. 6. Manufacturing That Eliminates Risk & Improves Reliability 6 Risks Using an Off the Shelf Cable  Inadequate Performance – EMI Shielding – Data Transfer – Ruggedization  Standard Offerings – Only available in select configurations  Availability – EOL, obsolesce, and long lead times  Volumes – Can you buy enough to support production volumes? Don’t settle for a cable that’s not a solution
  7. 7. Manufacturing That Eliminates Risk & Improves Reliability 7 Benefits of Using Custom Cable Assemblies
  8. 8. Manufacturing That Eliminates Risk & Improves Reliability 8 Customization of Features  Complete Customization – Select the exact wire AWG size desired for each leg – Choose between standard jacket colors – Tool up and extrude custom jacket per PMS pantone color – Match the shielding design to the application  Custom Overmolding – Use artwork files to add logos and text – Custom materials – Flexibility to make tooling modifications – Ruggedized strain reliefs Incorporate those nice to have and must have features
  9. 9. Manufacturing That Eliminates Risk & Improves Reliability 9 Customization of Features  Implement design features to pass qualification testing – Waterproofness – Radiated / conducted emissions and susceptibility – Salt fog  Employ specialty materials, processes – Fungal resistance jacket – Encapsulate PCBA, switches, sensors – LEDs to indicate status Consider adding passive components and PCBAs to your build plan
  10. 10. Manufacturing That Eliminates Risk & Improves Reliability 10 Customization of Features  Consolidate several discrete cables and components into one solution – Eliminate daisy chained assemblies – Add customized features to standard offerings Hybrid cable assemblies can address various design challenges
  11. 11. Manufacturing That Eliminates Risk & Improves Reliability 11 Custom Connectors  Use 3D modeling to create desired design – Solidworks, .STP, .IGS, etc.  Complete control of the design – Pin engagement – Customizable overmold  Add all those design pesky details – Beryllium copper coating to pins – Polarity markings  No EOL or Obsolesce – Custom tooling is catalogued and maintained By owning the tooling, obsolesce can be mitigated.
  12. 12. Manufacturing That Eliminates Risk & Improves Reliability 12 Use of Substitute Components  Custom cable assemblies can be design with form, fit, function equivalent connectors  Mitigate long lead times  Cost savings  Important considerations – Pin count, pitch, size – Polarization or locking feature – Interface tolerances – Footprint – Electrical rating – Material compatibility – EOL or planned obsolescence – Flammability rating Replace specialty connectors with form, fit, function equivalents
  13. 13. Manufacturing That Eliminates Risk & Improves Reliability 13 Incorporating Tests & Special Processes  100% Leak Testing – Install in fixture and test each cable assembly at 3.5 psi – Pressurize wire jacket and submerge in bath of isopropyl alcohol  Implement AQL Electrical Testing – Radiated emissions sweeps – Continuity testing, hipot testing Provide value by including additional assembly and processing steps
  14. 14. Manufacturing That Eliminates Risk & Improves Reliability 14 Incorporating Tests & Special Processes  Perform in process mechanical testing – Flexure, bend, and pull testing  Follow specialty processes and tests – ATP Procedure – Burn in – Ex. soak in liquid before assembly Provide value by including additional assembly and processing steps
  15. 15. Manufacturing That Eliminates Risk & Improves Reliability 15 How to Get Started With Your Custom Build
  16. 16. Manufacturing That Eliminates Risk & Improves Reliability 16 How to Get Started With Your Custom Build  Visit www.epectec.com/cable-assemblies  Review website for technical information  Summarize must have & nice to have requirements  Understand the application  Epec can help design your cable – Drawing creation – 3D modeling – Connector down select – Wire AWG and jacket review Engage Epec Early - Convert IDEAS into a DESIGN
  17. 17. Manufacturing That Eliminates Risk & Improves Reliability 17 How to Get Started With Your Custom Build  Don’t reinvent the wheel  Use standard components and connectors where possible  House tooling exists for many standard connector schemes and sizes  Avoid lengthy lead-times and MOQs by selecting common wire wherever possible Using standard wire and house tooling can save time and money
  18. 18. Manufacturing That Eliminates Risk & Improves Reliability 18 How to Get Started With Your Custom Build  Understand the project details: – What is your budget? – What is your timeline? – Who has design authority? – What are the qualification requirements? Budget and timeline have a tremendous impact on design options
  19. 19. Manufacturing That Eliminates Risk & Improves Reliability 19 The Steps to Developing a Custom Cable Assembly Production samples are required to verify the build plan Prototype Preliminary Concept ProductionInitial Design
  20. 20. Manufacturing That Eliminates Risk & Improves Reliability 20 The Steps to Improving a Custom Cable Assembly If you own the design, you can make modifications to improve performance Original Design Leak Test Failure Epec ProductionEpec Solution
  21. 21. Manufacturing That Eliminates Risk & Improves Reliability 21 Summary
  22. 22. Manufacturing That Eliminates Risk & Improves Reliability 22 Summary  Use an Off the Shelf Cable for the right projects  Don’t settle for an inferior cable assembly  Incorporate those nice to have and must have features  Engage Epec early - convert IDEAS into a DESIGN
  23. 23. Manufacturing That Eliminates Risk & Improves Reliability 23 Our Products Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards RF Products User Interfaces Flexible Heaters EC Fans & Motors
  24. 24. Manufacturing That Eliminates Risk & Improves Reliability 24 Q&A  Questions? – Enter any questions you may have in the control panel – If we don’t have time to get to it, we will reply via email
  25. 25. Manufacturing That Eliminates Risk & Improves Reliability 25 Thank You Check out our website at www.epectec.com. For more information email sales@epectec.com. Stay Connected with Epec Engineered Technologies Follow us on our social media sites for continuous technical updates and information:

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