Scour the web for a reliable interconnect solutions provider, and you’re sure to turn up dozens of manufacturers, each with a catalog of turnkey solutions to meet your application needs. While many product lines offer the performance and reliability to align with your specifications, there are certain situations that warrant a customized connector and cable assembly solution — especially if standard parts fail to meet the demands of an application.
Customizing a connector and cable assembly gives product teams a variety of options for how to enhance the performance of a solution. However, the benefits go far beyond performance alone.
Benefits of a Customized Connector and Cable Assembly:
- Increase product aesthetics/appeal
- Improve safety profile
- Lower product costs
- Add value and ROI
- Extend shelf life
- Meet unique application demands
- Ensure reliability
- Improve user experience
Here are just some of the many ways product teams can modify elements of a connector and cable assembly to better suit their needs or build an interconnect solution from scratch.
Customizable Connector & Cable Assembly Elements
Mechanical Features
Design details that are specific to how cables and connectors are adjoined.
- Pin sequence
- Keying
- Locking mechanisms
- Backshells
Connector Shape & Orientation
The literal shape of the connector head, which can be customized to fit into tight spaces or unique device designs.
- Circular connectors
- Rectangular connectors
- Straight overmold
- Right angle overmold
Mount Styles
How a connector and cable assembly is affixed to a device (such as a computer or appliance).
- Panel mount
- Free-hanging mount
- Board Mount
Coupling Styles
How one connector end mechanically joins with another connector end.
- Quick connect (Plastic)
- Snaplock
- Threaded (Metal)
- Bayonet
- Push-pull
Terminal Bonds
The method used to adjoin a wire to a wire or a wire to a terminal.
- Crimped
- Soldered
Wire Gauge
The diameter of the wire, which determines the amount of electricity the wire can carry safely and the amount of resistance present in an electric circuit.
- 10
- 12
- 14
- 16
- 18
- 20
- 22
- 23
- 24
- 26
- 28
Number of Contacts
The pins and sockets found on each connector end that fit together to complete an electrical connection.
- 2 through 12
- 14
- 18
- 20
Contact Materials
Typically a type of metal that determines the conductivity of the cable and connector and, thus, the strength of the electrical current.
- Silver alloys
- Gold
- Platinum
- Carbon
- Niobium
Insulation Materials
Materials used to prevent an electrical current from coming into contact with other wires, equipment, or users.
- Polyvinyl Chloride (PVC)
- Polyethylene (PE)
- Polypropylene (PP)
- Polyurethane (PUR)
- Chlorinated Polyethylene (CPE)
- Nylon
- Thermoplastic Rubber (TPR)
- Thermoplastic Elastomers (TPE)
Overmolding Materials
Materials used in an injection molding process to permanently combine a cable and connector into one single, seamless part.
- Polyvinyl Chloride (PVC)
- Polypropylene (PP)
- Acrylonitrile Butadiene Styrene (ABS)
- Thermoplastic Rubber (TPR)
- Thermoplastic Polyurethane (TPU)
- Polybutylene Terephthalate (PBT)
Get the guide: Everything You Need to Know About Overmolded Cables.
Aesthetic Properties
Details that enhance the appearance, installation, and user experience of a connector and cable assembly.
- Color
- Ergonomics
- Specialized packaging
- Miniaturization
Performance Properties
Design elements that physically enhance how a connector and cable assembly performs in a specific environment or application.
- Mechanical durability
- Temperature extremes
- Ruggedness/strength
- Tamper proof
- Water resistance
- Chemical resistance
Limitless Design Options
Product teams have a ton of flexibility when determining the best solution for their project. In some cases, a fully customized connector and cable assembly is best. In other situations, teams can save time and money by re-engineering an existing product. Either way, the best approach is to work with a cable and connector manufacturer with in-house engineering capabilities.
