Ready to unleash the potential of the interconnected world? At Meridian Cable, our custom cable assembly capabilities let you do just that. Our tailored solutions are your keys to seamless integration, dependable performance, and impressive interconnectivity. Whether you need simple, low-voltage hookup wires or complex overmolded breakout assemblies and coaxial cables, our capabilities run the spectrum of possibility.
Our engineered solutions offer total customization, with over 5,000 unique components and combinations. For each project, we’ll consider your equipment, environment, and transference needs to create a one-of-a-kind cable assembly just for you. With fast turnaround times, impeccable customer service, and total customization, we’ve got you covered for any and all custom cable assembly projects.
Outstanding Customer Support and Expert Care
Working with Meridian is easier than ever because we take care of everything. As a seasoned cable manufacturer with multiple decades of experience to our name, we’ve made a cable assembly for just about everyone. Which comes in handy when working with unique or specialized equipment.
Our supportive staff is here to ensure your success with your interconnectivity project. Whether you’re custom designing a cable assembly with our engineering team or replicating a common cable blueprint, we’re committed to helping you get the ideal connection solution for your problem. We value your success and are here to support you every step of the way.
We foster a robust collaborative approach with our customers to ensure they enjoy the best experience possible. Part of our ISO 9001:2015 certification includes continuous process improvement – including to our customer experience and service.
Optimized Design for Simplified Integration
Working with our design engineers puts their experience and brilliance at your disposal. With their expertise and unparalleled insight into cable assembly design, our engineering staff collaborates with you to create the ideal cable assembly for your equipment and connection needs.
We are all about efficiency, so our engineers work tirelessly to ensure a design is just right, saving time and frustration in the long run. Every new cable design undergoes a rigorous manufacturability review, ensuring a streamlined integration process, exceptional functionality, and reliable performance. Your integration process can be simple and speedy when every detail has been checked and rechecked. Plus, we’ve already digitally tested your cable project to identify and correct potential hiccups before they happen in the real world. So, by the time you receive your cable assembly, you can rest easy knowing it’s ready to integrate directly into your system.
Certifications You Can Count On
A cable is not worth a thing if you can’t rely on it. We’re proud to hold multiple certifications, adhering to and even exceeding industry standards across the board. We place ourselves under extreme scrutiny, ensuring every connector, cable, conductor, and component aligns with the highest quality standard for design and functionality. We take our quality control and quality assurance (QAQC) in our manufacturing very seriously.
We’re constantly adding new certifications to our inventory, planning for the future of cable assembly needs. Our strict adherence to industry standards lets our customers know they can rely on our products, such as tried-and-true cable assemblies, wire harnesses, and more. We want to be proud of everything we produce, so we hold ourselves to the highest quality standards.
Complete Cable Assembly Capabilities
Everything you need for a custom cable assembly is at your fingertips with our capabilities. Our comprehensive cable assembly services run the gamut of connectors, terminals, conductors, you name it. We have over 5,000 options to build the ideal connection solution tailored to your specific needs. From simple and standard to complex and custom, our catalog includes every component you’d ever need to craft an optimized, easily integrable assembly into your system.
Our conductor, terminal, and crimp options include:
- Wire-to-wire connectors
- Wire to board connectors
- Single and multi-row connectors
- Ferrules, splicing, and butt connectors
- Insulated/partially insulated terminals
- Spayed, fork, and ring terminals
- Standard and gold plating options
- Automated and manual crimp stations
- So much more!
That’s just the tip of the iceberg when it comes to our conductors, terminals, and crimps from which you can choose.
Custom Conductor Extrusion & Wire Preparation
Depending on the purpose of your cable assembly, you may need a higher-capacity conductor. Fortunately, we have the capability to custom extrude our conductors to the most precise measurement. The process starts with a massive spool of copper or other conductor material and ends with an ultra-precise, custom-extruded conductor.
As the conductor size can impact performance, capacity, and signal reliability, it’s essential we get this component just right. Additionally, we can create custom lengths to ensure optimal design for spatial limitations and equipment needs. When we build a cable from the conductor out, every detail, jot, and tittle is taken into account to create an ultra-precise cable assembly.
Ruggedization and Customization
Sometimes, cable assembly needs that extra something to operate in harsh environments. Poor weather conditions, outdoor situations, or hazardous environments have been the death of many cable assemblies. Our options include multiple avenues for quality and durability to adapt to any environment and working conditions.
Some of our options for toughening up your cable assembly include:
- Molded members, injection molded components, and mating housings
- Overmolded strain relief and PCBA assemblies
- Customized jackets for waterproofing
- Customized RTF potting, epoxy, capsulation, sleeping, and wraps
- Nylon braiding, shielding, and conductive over braids
- Organizational colorization and patternation
We can create a cable assembly to operate within just about any environment. With these organization and customization features, your cable assembly is ready for anything.
Shielding and Protection
Speaking of protecting your cable assembly, electronically noisy environments require additional protective elements for optimal performance and to avoid signal loss. Electromagnetic interference (EMI) or radio frequency interference (RFI) can wreak havoc on your equipment if your cables are not adequately protected.
We can integrate shielding directly into your cable assembly to help reflect and ground any EMI-related disasters.
Shielding options include:
- Braided wire, overbraiding, EMI, and RFI shielding
- Polyester or aluminum foil, braid spiral serve wire, foil tapes, or copper tapes
Whether you’re in telecommunications or an industrial field, shielding can make all the difference.
Additional Components and Sub-Assemblies
Custom cable assemblies often require other components and sub-assemblies. We include multiple customization options with additional components, routing, sub-assemblies, and more. When your cable assembly needs a little something extra, intricate design, or sub-assemblies within the blueprint, our engineers can take care of what you need.
These options include:
- HDMI, display ports, USB variants, LEDs, and fan assemblies
- PCBAs, battery terminals, housings, switches, grommets, and boots
- Embedded systems, microcontrollers, custom machined and sheet metal members
- Custom 3D printed components
- Additional sub-assemblies
- And more!
Whether your situation requires a complex design structure or simplicity, we will help design and create the perfect solution that meets all your requirements.
Stranding Construction
Stranding can significantly impact the performance and durability of your cable assemblies. Solid stranding offers simplicity and strength, ideally suited for applications when minimal flexibility is needed. However, this may not be what your situation requires. We take an in-depth look at the particulars of your cable assembly project to install the optimal stranding for your needs.
Stranding options include:
- Solid stranding
- Bunched stranding
- True concentric stranding
- Rope lay
Depending on your cable needs, your stranding can be one of the most critical components of your conductors. Our team can help you determine the appropriate stranding size and pattern for your needs.
Voltage
Naturally, your voltage capacity is one of the most critical elements of your cable design. If your voltage is not optimized for your equipment, it can lead to disastrous effects, including signal loss, equipment malfunction, or even combustion. We take great care to ensure your equipment’s voltage is just correct.
Voltage accommodations range from low 30V to high capacity 3000V.
Insulation & Jacket Materials
Adding a layer of insulation in your cable is one of the best defenses for your equipment. You can choose from a range of insulative materials, including:
- Cotton, nylon, kevlar, PVC, and fleece
To surround your cable, you’ll need a jacket. This element helps keep things contained while simultaneously repelling outside variables, like dust and moisture. You can choose from a range of materials to maximize your flexibility and level of protection for your cables.
Jacket material choices include:
- Polyethylene, PVC, silicone, vinyl, and more
Depending on your work environment and the needs of your cable assembly, these jacket materials can be selected to optimize performance and durability.
Get Your Project Going Today!
With experience comes the benefit of speed. Since 1994, we’ve been committed to high-quality cable manufacturing for connection solutions. Our rapid turnaround times, extensive prototyping and quality assurance testing, and reliability make us a premier option when you need a cable project done. With unparalleled service and meticulous attention to detail, our team can craft any cable assembly for any environment or industry.
If you’ve got a vision of a more connected world, we are here to help you fulfill that goal. Our team is standing by to make your interconnectivity dreams a reality. Contact our staff to start your cable project today!