Technical Cable Applications was founded in 2002 in Auburn, WA. Since then, we have grown to serve customers all over the United States, North America, and internationally. Our staff has expanded tenfold since our original startup along with our facility’s real estate, reflecting our commitment to growth and excellence.
M12 cable is one of the most commonly manufactured cable assembly types here at Technical Cable Applications. However, if you don’t have manufacturing or automation experience, you likely have never used one or seen one since they aren’t commonly used by consumers.
An M12 cable is a type of industrial Ethernet cable that uses a circular M12 connector. These connectors are designed to create a secure and sealed connection between devices, especially in environments where standard cables may not hold up.
The “M12” refers to the connector size and threading, and there are additional M-type connector types starting with M5 up through the aforementioned M12. What makes these cables stand out is their ability to maintain strong, reliable connections even in harsh conditions while still supporting high-speed data transfer.
Versatile M12 Circular Connectors
M12 cables are used across a wide range of industries where automation, movement, and environmental exposure are common.
You’ll typically find them in:
Robotics and automation systems
Warehouse automation setups
Machine vision systems
Aerospace and automotive applications
Medical devices
Agriculture and manufacturing equipment
Marine and utility environments
These are all areas where dependable data transfer is essential and equipment is often exposed to movement, vibration, or challenging conditions.
M12 Connector Uses and Applications
Industrial Ethernet plays a major role in modern automation. M12 cables are part of that ecosystem, helping devices communicate reliably across systems.
They are commonly used to connect sensors, machines, and control systems. Because of their rugged design, they help ensure that data transmission continues without interruption, even when equipment is constantly in motion.
Some assemblies are also designed for high flex cycle use, making them suitable for robotics and other applications where cables bend repeatedly.
One of the biggest advantages of M12 cables is how easily they can be customized for specific applications. As long as we have all the drawings, specifications, and materials, we can produce assemblies with:
Custom pinouts
Connector orientation adjustments
Integration with other connector types like M8 or RJ45
Custom configurations and layouts
And much more!
Our Manufacturing Benefits
M12 cables can be built using different methods, including assembled connectors or over-molded designs. Over-molding involves encasing the connector and cable in a protective material, creating a more durable and sealed connection.
We are able to use specialized mold dies to produce over-molded M12 cables in-house. This approach allows for both standard production and highly customized cable builds. We also offer nearshore manufacturing in partnership with two facilities in Guadalajara, which allows us to avoid reliance on connectors and materials from overseas in many cases.
Getting new custom cable assemblies manufactured is already a multi step, in-depth process, even for existing cable configurations that are tried and true. Assembly production delays can happen due to unforeseen external circumstances, such as material shortages, global politics, or shipping problems. As such, adding in complications with prototyping, testing, and making adjustments to the cable assembly before final production comes with significant risk of additional delays, complex problems to solve, and multiple rounds of testing before the final version is ready. As such, working with a manufacturer who is highly flexible, offers low MOQs (minimum order quantity), and can help solve problems as they arise is extremely important, so you can avoid budget bloat and get through snags or delays as rapidly as possible.
Reduce Lead Times with Nearshore Manufacturing and Assembly Production
We offer nearshore manufacturing with two partner facilities in Guadalajara, which enable us to provide lower MOQs and reduce lead times on prototype cable assemblies and wire harnesses, compared to many of our competitors. Now that we are able to offer nearshore options for many cable assembly types that were previously reliant on, or had to be entirely manufactured by overseas companies, our prototyping lead time is faster than ever. We can also minimize or fully avoid non-manufacturing delays associated with freighter shipping in many cases, since our direct partnership and close proximity to our partner facilities means the cables can be shipped directly via ground or air, rather than slowly coming over by boat.
Additional Best Practices for Improving Cable Assembly Lead Times
Whether you are working with us or with another cable assembly manufacturer for your prototyping needs, there are many ways to avoid unnecessary delays and problems with good planning and management. Some of the best practices we recommend for anyone tasked with bringing a prototype cable assembly to full production include:
Avoid unnecessary complexity in your initial drawing – Every additional connector or nice-to-have feature adds details that must be developed, tested, and certified before the final cable can be produced. If keeping lead times down is a priority, simplification is the best way to avoid delays before they start.
Create detailed documentation and specifications wherever possible – Your cable drawing and materials list should be as detailed as possible, to avoid confusion and incorrect assumptions that could result in additional delays.
Choose materials that are the most likely to be readily available over boutique or unusual ones – In many cases, assemblies do not need the most cutting edge, specialized materials to accomplish their intended purpose. Avoid choosing materials that can only be produced by one source, or are subject to frequent shortages wherever possible to ensure faster prototyping. This will also likely lead to easier manufacturing later on of the final product, for years to come.
Minimize the number of different vendors working on the same assembly – You may need to work with more than one manufacturer to get your final prototype assembly ready, but it’s generally best to avoid adding more vendors that touch the assembly. If your main manufacturer is able to handle all or most steps of your prototyping in-house, that will be your best bet if your goal is to keep lead times short.
Check if vendors have certifications that will take care of your testing and compliance requirements – We are ISO 9001:2015 certified and UL certified for cable assembly, which helps us cover many of our clients’ requirements by default. If you have a specific certification your assembly needs to meet, it’s best to choose a vendor who already has that capability so you don’t have to get it prototyped, then inspected, and prototyped again.
Contact Us About Your Prototype Cable Assembly
Ready to get started? Send your cable drawing and specifications to us at [email protected], or use the contact form here on our site!
If you’re in the procurement department for your corporation or business, you may be in search of a new cable assembly manufacturer or supplier. This can be due to all kinds of factors, but a few of the top ones we hear from new clients are:
New governmental requirements that affect federal manufacturing contracts – As new laws are passed and old ones are updated, your company may need to change where components are sourced from, or what materials they are made from to stay compliant. We offer nearshore manufacturing which can often solve the former problem, but each situation is unique.
Previous cable manufacturer is no longer able to meet their needs – Whether your business is expanding and you need to find the right partner to keep up, or your previous manufacturer can no longer manufacture your cables the same way, you may be forced to find a new supplier. We provide OEM orders along with custom prototyping, but some manufacturers only manufacture larger orders of OEM cables, or only provide custom cables without manufacturing at scale.
Existing cable manufacturing partner is not able to manufacture a specific product – Every cable assembly manufacturer has their specialties, but due to the massive variety of cable and harness types, there will always be some cable types that they cannot manufacture, or can’t offer competitive pricing for. For instance, other companies may refer customers who need M12 cables to us, while we may refer customers back to them for specific needs that aren’t a great fit for us.
Choosing the Right Cable Assembly Manufacturing Partner
This post will go over the top things to consider when searching for a cable manufacturer who can meet your current needs, and what to provide them with so you can get proposals back quickly.
Material Selection
Where are materials sourced from by the manufacturer?
This may already be top of mind if you are needing to find a new partner due to industry or government restrictions, but it’s important to know where the manufacturer will obtain the materials and parts to manufacture your cable with. Even if you are not required to only use components and materials procured within North America, or don’t need to have a highly detailed record of where every component was produced, you still need to know that your cable manufacturer of choice will have trustworthy sources for components and materials.
Industry Standards
What certifications does the cable manufacturer have?
You may need to only work with manufacturers that have a highly specific certification or qualification, such as ITAR for defense contracting in the United States. However, even if your cable needs don’t have a prerequisite like that, it’s best to choose a company that is provably qualified for the cable assembly work you need. For instance, we are internationally IOS 9001:2015 certified, and UL certified for the United States and Canada for cable assembly.
Cost Savings
Will this manufacturer help keep my costs down?
This may require speaking with the manufacturer’s sales team on the phone or in a video call, as this is a bit more nuanced to answer. The short version is that the right manufacturer will meet your needs for cable assembly manufacturing, while identifying opportunities to keep your costs down wherever possible. We do this by offering nearshore manufacturing options that can often help save on both assembly and shipping costs. Our engineers also have decades of expertise and experience in identifying materials and connectors that will do what is needed, but for a lower cost and/or quicker turnaround time.
Custom Cable
Do I need a manufacturer that can manufacture custom cables or prototype new ones?
This depends on how far along you are in the cable assembly process, and what you need additional assistance with. For example, we do not provide design of entirely new cable drawings, so we wouldn’t be a good fit for that step of the process. Meanwhile, some manufacturers do not provide prototyping services, or may have high MOQs (Minimum Order Quantity) that don’t work for your prototyping budget. We offer low MOQs thanks to our nearshore manufacturing partnerships, so if you need custom or prototype cables we’d love to hear from you!
OEM Bulk Cable
Do I need a manufacturer that can manufacture large orders of existing cables at scale?
If you have an existing cable assembly that’s ready to go, the most pertinent question is whether the manufacturer you choose has the capacity to turn around the quantity of cables needed, in a timely fashion. Smaller, custom manufacturers may take longer to complete a bulk OEM cable assembly order, compared to a larger company with more equipment and staff tailored for that kind of production speed. We have expanded our manufacturing capacity significantly over the past decades, and can provide large bulk orders that we wouldn’t have been able to initially.
Quality Assurance
Can I trust this manufacturer’s quality control procedures?
It’s important to choose a manufacturer with proven and industry standard quality control systems. We hold to IPC/WHMA-A-620 Standard Revision E for our quality control and inspection regulations, and utilize automated work instruction tools developed in partnership with our friends at Scout Systems to standardize every process down to minute details. This also helps us track exactly where each part and component we use comes from, in order to isolate problems if they are found in the quality inspection process.
Medical assemblies can be expensive to develop, due to many factors. These include the potential for unexpected revisions after FDA rule changes or prototype disapproval, strong durability needs for cables used in proximity to radioactive or electromagnetic currents, and low voltage limits that require careful development.
This means that keeping costs down and striving for FDA compliance is paramount, since the final version of any new cable assembly or build of an OEM by a different manufacturer will always be under tight scrutiny. This post will highlight some of the best ways we’ve found to keep costs on cables for the healthcare industry down.
What This Will Not Cover
Before we get into the specifics, here are a couple of caveats on the scope of this educational post:
Healthcare related cable assemblies and wire harnesses cover a wide gamut of needs and applications, and therefore the methods of keeping production costs down vary a lot depending on the assembly type. These are general principles that apply to most cable assemblies, but may not to all.
We also do not provide cables that touch patients’ skin such as ECG cables, so we will not be going over anything related to that technology. You can refer to theCardinal Health study on single-patient use ECG cable to get more insight on that topic.
1. Use Readily Available Wires, Materials and Components for Lean Manufacturing
Specialty items can offer incredible performance benefits or make installation easier: for example, a new type of specialized cable jacket may be extremely durable compared to more readily available options, and therefore make the finished cable assembly have a much longer usage life. However, we always have to determine if the benefit of the specialized component is worth the additional cost, or if it will increase lead times due to difficulty obtaining the needed materials.
Lean manufacturing is all about finding opportunities for cost savings that will not adversely affect the final product. In many cases, a specialized component will offer a benefit that is not absolutely necessary, making the potential upside less worthwhile while still increasing costs and turnaround times. We recommend only choosing unusual or completely new components when it has been deemed as a requirement, for accomplishing what the cable assembly will be built to do.
2. Utilize Nearshore Manufacturing or Part Sourcing Where Possible
It is not always possible to get parts made in the United States and it can be expensive as well, but an alternative exists that does not require overseas shipping or logistics: nearshore manufacturing. Technical Cable Applications partners with two excellent facilities in Guadalajara that help us reduce lead times, offer lower MOQs for custom requests, and save on costs overall thanks to avoiding overseas shipments and delays.
We recommend working with cable manufacturers who provide nearshore manufacturing options, or are partnered with reputable nearshore manufacturing companies, as the cost benefits of these partnerships should be carried on to you and keep you from nightmare scenarios where overseas parts are delayed well past the deadline, or put on hold entirely due to global events. You may also find a quality boost over using overseas components, in some cases!
3. Choose House Tooled Connectors from Major Medical Cable Assembly Manufacturers over Building Custom Tools
While we and other custom cable manufacturers can provide custom tooling and dies when absolutely necessary, these processes add a significant amount of time to pre-production and prototyping processes, and therefore must be chosen only when it is necessary to do so. A cheaper method is to choose to source connectors from one major cable manufacturer in the healthcare space like TE, GE or Phillips that will all work together and not need customization, since those companies have in house tooling that is ready to go.
This will avoid needing to pay extra for custom tooling, and make the assembly easy to manufacture at scale. The downside is having to work with the limitations of existing connectors to accomplish the assembly’s needs, but with creative engineering and cable drawing it may help with cost reduction.
4. Use the Fewest Number of Connectors for Additional Cost Savings
Finally, it’s best to simplify the cable assembly’s drawing as much as possible with the fewest connector points and components possible. Unless a connector or PCB (printed circuit board) is absolutely necessary for the necessary functions of the assembly in all instances, it may be better to remove it and find a way to accomplish the same need via other components retained in the drawing.
This is a difficult process and may not be possible if the assembly is already using the minimum number of components, but can result in significant cost savings for the final production order of thousands of assemblies.
It’s no secret that the international economy is particularly volatile in 2025, and tense relations between the United States and some of the main overseas manufacturing nations are causing uncertainty for many corporations and companies that rely heavily on trade with those locations.
These issues and the difficulty in projecting what will be available for overseas manufacturing in the future may be causing you to consider alternative manufacturing options. In that case, choosing Technical Cable Applications for your cable assemblies is a great way to get a head start!
Decrease Your Reliance on Overseas Cable Assembly Manufacturing with Technical Cable Applications
Founded in 2002, Technical Cable Applications has been manufacturing cable assemblies at our facility in the Pacific Northwest for over two decades. We have grown exponentially since our founding, going from a small company that built boutique cable assemblies to one of the largest custom cable manufacturers on the continent.
We have continued to offer custom, highly specialized cable assemblies for unusual applications with the same flexibility and eye for innovation for the past two decades.
However, we have also grown to the point of building harness assemblies for massive OEM orders on behalf of some of the largest companies in the USA, across dozens of industries and thousands of highly varied applications.
Here are some of the top industries we have served as a cable manufacturer since our inception:
Telecommunications
Marine
Automotive
Energy
Agriculture
Medical
Construction
Nearshore Wire Harness and Cable Assemblies Opportunities: Manufacture with TCA to Take Advantage
Not only is our facility located here in the United States, but we are partnered with two excellent facilities in Guadalajara that have allowed us to do the majority of our manufacturing and part sourcing in North America.
While some third-party parts or connectors may only be made overseas and still require shipping by cargo boat, we do as much as we can in the US and North America to improve lead times, lower MOQs, and maintain higher quality for all our assemblies custom built for your needs.
We manufacture almost any cable type, and can utilize most commonly used connectors and materials, including but not limited to the following:
M12 – M8, M5 and all pin types and variants within the M12 family of connectors
Coaxial – micro coaxial, triaxial, RF, and most/all variants of coaxial cables
USB – USB-A, USB-C, USB-B, Micro USB, and most variants of USB connector types
Ethernet – Cat5, Cat6, twisted pair, and most modern or classic Ethernet cables and connector styles
Media cables and assemblies – DisplayPort, HDMI, SATA, XLR, and most audio/visual specialized cable types
Overmolded cables – Highly durable shielding for cables to resist extreme temperatures, interference, high pressure, foot traffic, etc.
Battery cables – Most electric battery cable charging types
Highly Reputable Cable Manufacturer Founded and Operated in the USA
Our close working relationship with our partner facilities allows us to directly ensure that rigorous quality control is maintained at every stage, and our UL and ISO 9001:2015 certified processes there and in our Washington state facility allow us to track every single part, material and cable back to its original source in the event of a problem. We’re also ITAR certified.
Send Specifications and Drawings for Your Cable Assemblies or Harness Assemblies to Get Started
Please send your cable drawing and any necessary NDAs to us at [email protected], or fill out our online form and attach your drawing and documentation to get a quote*!
*Please provide cable drawings and all documentation available when contacting us so we can quickly give you an accurate quote. We will do our best to research specifications and materials if a drawing is not available, but if no documentation exists that may need to be created first before we can proceed.
In today’s gadget-driven world, USB cables have become an indispensable part of our daily lives. From charging smartphones to connecting devices, these cables vary widely in shape, size, and function. This guide will illuminate the visual differences and uses of the most common USB cable types, ensuring you select the right cable with ease whether you’re just trying to purchase the right one for your personal needs, or if you’re in need of bulk USB cable assembly manufacturing for industrial or business applications. If the latter applies to you and you need a reliable cable manufacturing partner, please contact us at [email protected] with your cable drawing and required specifications!
Most Common USB Cable Types Explained
1. USB-A
Visual Identification: The quintessential USB connector, USB-A is a flat and rectangular plug that’s often found at one end of most USB cables. It usually connects to host devices such as computers or power outlets.
Introduction and Use: Introduced in the mid-1990s, USB-A remains the standard for connecting peripherals like keyboards, mice, and external storage devices. Commonly used for data transfer as well as charging, it supports data transfer rates of up to 480 Mbps for USB 2.0 versions and up to 5 Gbps for USB 3.0.
2. USB-B
Visual Identification: USB-B connectors are noticeably square with beveled corners on the top. They are less common in consumer electronics and are often seen connecting to larger devices like printers and scanners.
Introduction and Use: Around since the original USB standard, USB-B is primarily used for data transfer and charging larger devices. With USB 3.0 variations, identifiable by additional pins and often a blue internal color, data transfer speeds can reach up to 5 Gbps.
3. USB-C
Visual Identification: Featuring a small, sleek, and oval design, USB-C is reversible, meaning it can be plugged in either way without issue—an ergonomic advantage.
Introduction and Use: Introduced in 2014, USB-C has quickly become the universal standard in modern devices, prevalent in smartphones, laptops, and tablets for both data transfer and charging. It supports up to 10 Gbps for USB 3.1, speeds of 20 Gbps for USB 3.2, and is capable of 40 Gbps with Thunderbolt 3 and 4 technology.
4. Mini-USB
Visual Identification: Mini-USB comes in a smaller size than USB-A or USB-B, with a trapezoidal shape. It’s typically found in old models of MP3 players and cameras.
Introduction and Use: Common in the early-to-mid 2000s, mini-USB served for connecting smaller personal electronics and offered 480 Mbps data transfer rates like USB 2.0.
5. Micro-USB
Visual Identification: A more compact connector than mini-USB, micro-USB has a flatter and narrower form, and is somewhat trapezoidal with a wider top.
Introduction and Use: Released in the late 2000s, micro-USB became the standard for older Android phones and various portable devices, offering data speeds up to 480 Mbps (USB 2.0) and charging capacities.
Exploring Lesser-Known USB Variations
While the more common USB types tend to dominate the scene, it’s important to also recognize some of the less common variants. These connectors cater to specific devices and uses, and understanding them can offer a complete picture of the USB landscape.
1. USB-A SS (SuperSpeed USB-A)
Visual Identification: A step up from the traditional USB-A, the USB-A SS connector can often be identified by a blue color inside the port (though this isn’t always the case). The external shape remains the same as the standard USB-A.
Introduction and Use: As part of the USB 3.0 standard introduced in 2008, USB-A SS supports faster data transfer speeds of up to 5 Gbps. This variant is used extensively in devices that require rapid data transmission, such as external hard drives and Solid-State Drives (SSDs), allowing for efficient data backups and file transfers.
2. USB Mini-B
Visual Identification: The USB Mini-B connector resembles the mini-USB type with its slightly trapezoidal shape, yet it contains an additional pin compared to the standard mini-USB.
Introduction and Use: Often found in older camera models and some legacy mobile devices, this connector type was popular in the early 2000s. While being largely phased out in favor of micro-USB or USB-C, mini-B was pivotal for synchronizing and charging smaller electronics at data rates up to 480 Mbps.
3. USB 4-Pin
Visual Identification: The USB 4-pin looks like a simplified version of the larger USB connectors, often used in uncommon situations to deliver specific functions. It lacks the notch and traditional USB housing seen in other types.
Introduction and Use: It’s typically seen in proprietary systems or specialized applications, providing both power and data transfer but at limited rates compared to mainstream USB styles. Primarily, its function depends on the device it was designed for, making it less adaptable.
4. Micro-B and Micro-B SS (SuperSpeed Micro-B)
Visual Identification: The Micro-B connector is quite similar to micro-USB but has a slightly different pin setup, with additional connections visible. The SuperSpeed Micro-B variant is known for its bifurcated form: one standard micro-USB side and an additional smaller pin section.
Introduction and Use: Micro-B was primarily used in smartphones and tablets before USB-C standardization. With the advent of formats like USB 3.0, the Micro-B SS version found its place in external hard drives, enabling SuperSpeed data transfers up to 5 Gbps, thereby enhancing external storage performance considerably, before being mostly replaced by the more ergonomic and faster USB-C.
Specifications and Usability
Knowing your USB cables doesn’t just help in identifying them visually, but also helps understand their specifications regarding data transfer and usage contexts. USB 2.0, 3.0, and beyond vary in their data transfer capabilities, where higher versions offer backward compatibility but greatly increase transfer rates. Understanding these distinctions can help in choosing the right cable for either transferring files or efficiently charging a device.
Conclusion
Understanding USB cable types can simplify connecting your devices, maximizing performance, and ensuring compatibility. Whether you’re a tech enthusiast or simply dealing with the cords that power your world, knowing which cable goes where is invaluable.
At Technical Cable Applications, we specialize in the bulk manufacturing of a wide range of cable assemblies, from USBs to other essential data and power solutions like Ethernet, M12, and coaxial cables. We hope this guide serves your needs and helps you navigate the vast landscape of USB technology with confidence. If you’re in need of USB cable assembly manufacturing for your business, government or industrial needs, please contact us at [email protected] with your cable drawing and any necessary NDAs!
Complexity in cable assembly manufacturing grows incessantly, compelling producers to grapple with intricate designs, precise specifications, and relentless pressure to optimize productivity, while maintaining the quality at the highest possible standard.
Innovation is the linchpin.
Adopting advanced manufacturing technologies and methodologies, including work instruction software, streamlines processes and enhances efficiency, meeting the demands of an ever-evolving industry.
From Handcrafting to Automation
Though cable assembly manufacturing can be an extremely labor-intensive process, cable assemblers are integrating sophisticated automation technologies that bolster consistency, minimize human error, and accommodate the complexities of modern cable assembly production. This evolution supports the aspirations of assemblers and fabricators for heightened productivity, paving the way for unprecedented levels of innovation and customer satisfaction.
Early Manual Techniques
In the initial stages of cable assembly manufacturing, each connection was carefully made by hand. This process was not only time-consuming but also required a high degree of skill and precision, restricting production capacity.
Operators used an array of hand tools, like wire strippers and soldering irons, to assemble cables. Each wire had to be cut, stripped, and soldered or crimped individually, leading to lengthy production cycles.
Early cable manufacture was a meticulous artisanal craft that relied on the steady hands and keen eyes of experienced workers.
Despite advances, these manual techniques established foundational skills and standards that persist in the industry. They underscored the necessity for precision and the value of craftsmanship in creating reliable connections. This groundwork shaped the evolution toward mechanization and automation.
Introduction of Semi-Automated Processes
The advent of semi-automated technologies marked a significant milestone in cable assembly manufacturing, fostering efficiency and consistency.
Implementation of Cutting Machines streamlined the wire cutting process, reducing the variability inherent in manual cutting.
Crimping Machines advanced from manual to pneumatic and eventually semi-automatic operation, enhancing connection uniformity.
Pre-Programmed Stripping Machines offered precise insulation removal, mitigating the risk of wire damage.
Automatic Soldering Stations provided consistent solder joints while minimizing the potential for human error.
Work Instruction Software began guiding operators through the production process, ensuring adherence to specifications and minimizing deviations.
With these machines, operators could oversee multiple stages simultaneously, substantially increasing throughput without sacrificing quality.
Investments in semi-automated systems allowed for scalable production capacities, aligning with the burgeoning demand for cable assemblies across various industries.
The Digitalization Impact
The advent of digital technology has marked a significant transformation in cable assembly manufacturing, introducing a new epoch characterized by unparalleled precision and efficiency. Within this digital realm, work instruction software has emerged as a cornerstone, effectively revolutionizing the transmission of intricate assembly knowledge. By digitizing and centralizing instructions, this software mitigates the risk of human error, propelling the industry towards a future where consistency and quality are augmented by an unwavering adherence to detailed digital directives. Consequently, assemblers and fabricators are empowered to exceed customer expectations with every meticulously crafted product.
Future Trends
Advanced materials, including high-performance polymers, will revolutionize the durability and functionality of cable assemblies, shaping customer expectations.
Connected and automated manufacturing processes, leveraging technologies like Artificial Intelligence (AI) and the Internet of Things (IoT), will drive efficiencies and elevate the precision and scalability of cable assembly production, meeting the upsurge in demand for increasingly complex systems.
Digital twin methodologies and predictive maintenance will emerge as standard practices, enhancing product lifecycle management and operational reliability.
Cable molding is used for all sorts of power and data transmission cables, and is more prevalent than the average consumer might realize. For instance, many consumer grade HDMI and USB cables have basic molding included to provide protection during connection and disconnection.
If molding is so commonplace nowadays, one might ask, then why are we writing about it? To put it simply, there are a great number of styles of cable molding that differ a lot from each other in terms of usage, and the manufacturing process. The basic molding you’ll find on many consumer grade cables is not sufficient for all applications so overmolded, industrial strength and custom molded cables are needed in many instances. We’ll describe the general molding manufacturing process that we use, and how we customize cable molding for customers based on their requirements and needs here.
Cable Molding Manufacturing
The simplest explanation of how cable molding is made, is that pressure is used to force material into a mold cavity or what we typically call a “die”, with the desired shape the final mold needs to be. Molding machines automate and simplify this process. We use MoldMan thermoplastic machines to overmold cables by the thousands at Technical Cable Applications. We use special thermoplastic material, such as the polyamide Macromelt OM 646, and heat it to up to 475 degrees Fahrenheit depending on what the final molding needs. Our MoldMan machines allow us to time the injection and clamping processes perfectly with up to 2 tons of force!
Custom Cable Molding
If a customer comes to us with a need for their cables to be molded with a custom raceway solution, we’ll identify 3 main things:
What is the application for the cable? Usually we have a cable drawing from the customer but oftentimes additional information is needed to ensure that the molding will be right for the client’s needs and survive the environmental hazards it will be put through.
Do we need to have multiple configurations of molding or just one, and do they have custom dies already or will we need to produce some? Custom molding dies can be created with multiple shapes and configurations, so that we can quickly manufacture multiple different mold shapes. This is helpful when the client needs a few different types of molding, but unnecessary if they just need one type of mold.
What material is best? The most common one we use because of its versatility is the aforementioned Macromelt OM 646. It has a hardness rating of 92A and a very wide range of service temperatures so it is more than sufficient for many applications. However, if a softer or firmer hardness is needed or if the environment where the cables will be utilized is over 257 degrees Fahrenheit, there are many other options for polyamides that will do the job.
Our technicians are extremely knowledgeable about cable molding, and we utilize automated work instruction tools to ensure that every step of the manufacturing process of cables is done properly. You can trust our team with your bulk cable order from prototyping to final production, just send us your cable drawing to get started!
The medical field is unique in that the individuals who are most close to the equipment, cables and tools used are often in very vulnerable states and therefore all equipment used must be 100% safe and have little to no risk of additional injury in the event of a cable failure. Unlike industries like construction or power where everyone is wearing protective equipment at all times to prevent injury, any equipment used for medical procedures, diagnostics, pain prevention and comfort must be completely free from risk of electrocution or other injury.
This is compounded by the need for reliability, as cables transferring electronic information from ECG cables about a patient’s brain activity cannot afford to fail and transmit incorrect data, nor can a surgeon’s equipment be expected to fail occasionally during an operation without dire consequences occurring. Meanwhile, medical facilities need so much more than ECG cables as well, as medical equipment can often draw quite a bit of power, and therefore durable power cables are a necessity in most facilities. These cables require additional shielding for the purpose of protecting patients and medical staff from injury.
Another common need that is only becoming more difficult with time as file sizes increase, is transfer of extremely high-resolution MRI and diagnostic images from computer to computer, or worse from a local computer to a cloud server. This requires high speed Ethernet cables that can transfer and upload hundreds or thousands of megabytes per second, so that extremely important data and medical imaging can be viewed right away by experts and save time and hassle during important decision making processes.
In short, the medical industry has unique components in terms of the needs for safety and has important legal and ethical requirements to consider for any facility or equipment manufacturer. These stringent safety requirements, combined with increasingly more demanding power and file size requirements, mean that it’s best for medical industry leading companies to choose a qualified cable manufacturer for their bulk cable needs.
While wireless technology has become commonplace in the everyday consumer’s home, with features like WiFi, 5G cellular connectivity, and even wireless charging for devices becoming highly popular, many consumers’ homes still utilize the classic Cat-6 connector throughout the home. Routers connect to other devices via Ethernet and LAN wires, and many power users still prefer the speed and reliability of wired connections over wireless options. This reliance on wired Ethernet connections increases exponentially for business needs, as just about any company that has even basic servers in-house will need lots of Ethernet wires or even basic assemblies to connect everything together. However, the types of Ethernet and Cat-6 connectors and the materials used for wires or cable assemblies will vary wildly depending on the business facility’s industry, environment and level of hazardous factors involved. Here is a brief guide on the types of scenarios where industrial strength Ethernet cables and wires are needed, and when higher speed but lower durability options are more viable.
The Benefits of Industrial Ethernet Wires and Cable Assemblies
Extreme durability in harsh environments
Industrial grade cables are typically built with tough materials, larger gauges, and shielded construction to ensure that they will continue working in harsh conditions, whether those conditions are extreme temperatures, liquid resistance, electromagnetic interference etc. This is extremely important for all kinds of industrial facilities that manufacture products using high temperatures, corrosive chemicals or strong vibrations as they can’t afford to have wires or cables failing in those conditions.
Determinism to ensure that data is delivered on time, every time
Rather than being optimized for speed, industrial Ethernet cables and the protocols they are compatible with provide determinism. This allows engineers to ensure that data packets arrive exactly when they are supposed to. This is necessary because equipment in an industrial or manufacturing setting needs to communicate packets of data at very specific times to ensure that the production line or process does not miss important steps, or fail because one piece of equipment wasn’t able to send its update to the next. While we just manufacture the cables used for industrial Ethernet applications, we ensure that our industrial cables meet all specifications from our customers so that they will be able to provide exactly what’s needed.
The Drawbacks of Industrial Ethernet Wires and Cable Assemblies
More expensive than standard ethernet cables
Because of the extra strong materials and special construction methods used to protect the transmission of data under harsh conditions, the obvious caveat for industrial Ethernet wiring and cable assemblies is that they are much more expensive to produce than your basic, commercially available LAN wire or cable. This means that unless that extra durability is needed, companies may be able to save with having less durable, but more economical Cat-6 cables used.
Lower speeds than what the fastest standard ethernet wires can support
Gigabit Internet speeds are now achievable for consumers in large cities across the United States, but to access that speed you won’t want to be using an industrial Ethernet cable. These cables are intended for smaller packet transfer needs and optimized for durability over speed, as the needs for industrial applications rarely require more transfer speed than 100 megabytes per second. If you’re needing to download and upload massive files every day, like extremely high resolution medical imaging or IMAX film footage, industrial Ethernet cables won’t be able to support the speed you need so other options may be best.
We hope this guide was helpful for anyone who is unfamiliar with the difference between industrial and commercial grade Ethernet cables, and what might be best for your needs. If you are with an industrial company in need of a better source for your Ethernet cables, please contact us and let us know what you need. We’d love to see your cable drawing if you have one and find out how we can assist you!
