Cable Assembly Design Criteria

Often times, minor details can substantially increase the cost and the complexity of a cable assembly, and may not be necessary.

Here are some ways to keep quality high and hold costs down:

• Supply full-scale drawings.
• Give precise dimensions with loose tolerances. Keep tight tolerances to a minimum use three decimal places with a tolerance of +/- .030 inches.
• Specify all dimensions from the connector reference plane.
• Avoid direct marking; use shrink tube markers or self-laminating labels.
• Specify center and outer conductor material if there are any special requirements.
• Design bend radii as large as possible.
• Specify the cable or connector, but state "or equivalent" if possible. Different manufacturers often make identical parts but with wide variance in cost.
• Specify electrical properties only across desired frequency ranges, as over-testing can be expensive.
• Avoid female terminations since the connector may require special orientation.

See our blog post to learn how we turned a napkin sketch into a production ready cable assembly.

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Cable Assembly Process

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