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.