Custom Cable Assemblies Manufacturer

Meridian Cable Company is a cable manufacturing and assembly firm that provides quality services across multiple industries. We provide full lifecycle services, from product start up through volume manufacturing, including the creation of qualification samples, and conducting prototype runs and offering pre-production testing. We offer value-added services through our on-staff engineers, and have broad sourcing capabilities. Plus, our expert design team creates custom cable assemblies for more than 70 percent of our customers.

We serve customers from facilities in two countries, located in St. Augustine, Florida and Tanggu, China. We own and have direct communication with the team in our Chinese facility, controlling quality. Products are 100% tested before shipping in these areas: continuity, integrity, polarity, and functionality.

Our company has more than 25 years of experience in serving customers in numerous industries, including medical, industrial control, broadcasting, telecommunications, retail security, and much more.

A wire harness can range from two wires with basic end terminals to a complex web of connectors and terminations. As harnesses become more complex, they often need customized manufacturing, with special shapes and sheathing, grommets, strain reliefs, mechanical fastening, over-molded connectors and more. If you’re reviewing wire harness manufacturers to find one that suits your needs, then we invite you to contact us.

A cable, meanwhile, consists of two or more wires that run together, often bonded or braided together. Cable assemblies are similar to wire harnesses, but they have more durable sheathing that may be more appropriate if heat, moisture, friction and/or abrasion is a significant concern.

A wire harness keeps wires together and can range from a simple solution to a more complex one. Harnesses play an essential role in virtually any project that requires electricity, keeping wires and cables organized and pointing in the appropriate directions. When wires become “crossed,” an entire system—such as an engine or computer—could go down. These harnesses also keep cables and wires safe. Plus, when they’re installed using best practices, other electrical professionals will know how something is assembled. If you’re looking at wire harness manufacturers for your projects, then we invite you to contact us.

At its simplest, custom cable manufacturing and design will provide your company with a customized solution to meet your most exacting requirements for cable manufacturing and assembly. Benefits of custom cable assemblies including having your performance needs precisely met, with personalized attention given to your challenges and solutions.

We use a wide range of materials and can customize cable design, manufacturing, and assembly to fit a wide range of price points and budgets. Customizable features include conductor sizes and colors, stranding sizes, conductor insulation materials, fillers, wraps and shields, jacket materials, cable types, and more.

 Our products are 100% tested before being shipped out, tested for continuity, integrity, polarity, and functionality. To ensure the highest in performance, we use advanced testing and inspection equipment and techniques, and we can work with you to get your product certified through most certification industries.

We provide customized solutions for numerous industries, from start to finish, including volume manufacturing and assembly. We will work with your company to determine your exact custom cable assembly needs, starting with the cable itself. Customizable features include conductor sizes (from 34 gauge to 12 gauge), a wide range of conductor colors (with cables also able to be marked with stripes, dashes, or text), stranding sizes (from .0002 inches to 0.01 inches), and materials (bare copper, tinned stranding, tinned conductor, or plated with precious metals), conductor insulation (with varied hardness or softness), fillers, wraps, shields, jacket materials, cable types, wire, and more.

We serve as cable assembly manufacturers for a wide range of industries, including for industrial controls, the medical industry, telecommunications, themilitary, and much more, including for the automotive industry, energy industry, broadcasting and more. If you’re in need of a custom cable assembly manufacturer, we invite you to contact us to discuss your needs. Our extensive industry knowledge, design experience, wide range of products and more allows us to customize products for industry-specific requirements. 

When you work with Meridian Cable Assemblies to create custom cable assemblies, we will analyze your precise challenges and requirements, devising a solution that works for your unique needs. You will receive personalized attention, rather than needing to choose assemblies from a list, ones that don’t provide the precise solutions you require. 

We offer a wide range of materials in a spectrum of sizes, thicknesses and more, and can customize your cable design, manufacturing and assembly to a specified budget. Customizable features include the sizes and colors of conductors, conductor insulation materials, and stranding sizes, along with fillers, wraps and shields, jacket materials, cable types, and more.

Another benefit of custom cable assemblies include how we 100% test products before shipping them to you, as we test for continuity, integrity, polarity, and functionality. We use advanced testing and inspection equipment and techniques to ensure the highest in performance, and can work through the production certification process with you in most industries.

We have significant experience in designing and producing overmolding for numerous industries in a wide variety of applications. Because we maintain an inventory of more than 5,000 molds, we can surround your components with plastic in a way that fits your precise requirements. Custom molding features include enclosure strain relief to protect your cable from bend failure, using a choice of materials. We also customize connector strain relief to avoid conductor failure, again available in a variety of materials.

Additional customizable features include breakouts to overmold where conductors leave a cable, seals and glands to keep unwanted substances out, cable stops to transfer force to anchor points to keep connections from being compromised, and conductor sizes, colors, and markings. We customize stranding sizes, conductor insulation materials, fillers within the cable to maximize performance, wraps and shields to prevent abrasion, cable types, wire, and more.

For your cable manufacturing and assembly to be a success, it’s crucial that the right wiring choice is made. Single-stranded wiring is typically less expensive, but is not as flexible, which can lead to metal fatigue and/or wire snapping. This makes single-stranded wiring best for products that don’t involve much movement, and it’s typically used in smaller gauge applications. Multi-stranded wiring involves more extrusion and stranding rounds, which brings about a higher cost. This choice is more flexible and less susceptible to metal fatigue or cracking, and is a better solution for wiring that needs to bend and maneuver. Multi-strand wires will encounter less resistance because of its increased surface area. There can be challenges with this choice if connectors soldering or terminal soldering is needed, and this type of wiring is better suited for applications needing a crimp connector.

When choosing a cable assembly manufacturer, ask them about their procedures, including their design processes. If you need custom cable assemblies, does a company you’re considering offer recommendations for materials and construction processes? Does the company understand installation conditions? Do they understand the entire manufacturing process that will need to take place?

When talking to cable assembly manufacturers, get a good sense of whether they understand how your final product needs to function and whether all design features are being considered. How will they ship your cabling? How will they prevent tangles? Are they willing to custom package and ship your materials?

What are their quality control testing procedures? Do they discuss crimp compacting ratios and pull testing? Do they laboratory-test under harsh conditions to ensure optimal performance? How will your materials be labeled? Find more information about what to ask cable assembly manufacturers.

To keep your production running smoothly, and to have an end product that performs in the way your customers need, it often makes sense to work with an expert cable manufacturing and assembly company to create prototypes. This is especially important if you have custom cable assemblies that are required to meet specialized needs of your customers.

Prototyping can ultimately save you money for multiple reasons, including that it allows you to identify supply chain issues that need addressed before going into full production. By discovering, early on, that certain parts are overly expensive or have limited availability can help you to reduce your overall costs and help to ensure component availability. Having an understanding of your costs and potential challenges, and working through them on a smaller scale, allows you to make adjustments and more informed decisions throughout the entire process.