There are numerous scenarios when an ordinary off the shelf cable will work just fine for the desired application. Typically, off the shelf cables are designed and manufactured in common configurations, lengths, colors, connector styles, etc., that cover a plethora of customers’ needs. For example, there are thousands of different black 3-foot USB cables that are readily available and in stock through various online and brick and mortar retailers. But what if you knew that you needed 10,000 black 3-foot USB cables? Cheaper options may exist for an order quantity of this size. Or what if you needed a black 3-foot USB with additional shielding that can withstand EMI emissions? Or instead of a black cable, you needed a navy blue overmold that matches your company’s branding and logo? In these scenarios there is a high probability you will save time and money and get added functionality by tooling a custom cable with a full-service cable supplier like Epec Engineered Technologies. Why settle for an off the shelf solution when you can have everything you want in a custom cable assembly? Listen to this webinar as we discuss how off the shelf cables simply can’t compete with custom cable assemblies. For more information on our cable assembly solutions visit https://www.epectec.com/cable-assemblies/.

1. Manufacturing That Eliminates Risk & Improves Reliability
Off the Shelf Cables Can’t Compete with
Custom Cable Assemblies
02.21.2019

2. Manufacturing That Eliminates Risk & Improves Reliability
2
Agenda
 When to Use an Off the Shelf Cable
 Risks Using an Off the Shelf Cable
 Benefits of Using Custom Cable Assemblies
 How to Get Started With Your Custom Build
 Summary

3. Manufacturing That Eliminates Risk & Improves Reliability
3
When to Use an Off the Shelf Cable

4. Manufacturing That Eliminates Risk & Improves Reliability
4
When to Use an Off the Shelf Cable
 When your system design can support it
– Length, connector configuration, etc.
 Stock availability
– Review distributor stock position
 Demand volumes matter
– 10 pcs vs 10K pcs
 Where are you in the development process?
– What will your device be used for?
Consider using a stock off the shelf cable for proof of concept testing

5. Manufacturing That Eliminates Risk & Improves Reliability
5
Risks Using an Off the Shelf Cable

6. Manufacturing That Eliminates Risk & Improves Reliability
6
Risks Using an Off the Shelf Cable
 Inadequate Performance
– EMI Shielding
– Data Transfer
– Ruggedization
 Standard Offerings
– Only available in select configurations
 Availability
– EOL, obsolesce, and long lead times
 Volumes
– Can you buy enough to support production volumes?
Don’t settle for a cable that’s not a solution

7. Manufacturing That Eliminates Risk & Improves Reliability
7
Benefits of Using Custom Cable Assemblies

8. Manufacturing That Eliminates Risk & Improves Reliability
8
Customization of Features
 Complete Customization
– Select the exact wire AWG size desired for each leg
– Choose between standard jacket colors
– Tool up and extrude custom jacket per PMS pantone color
– Match the shielding design to the application
 Custom Overmolding
– Use artwork files to add logos and text
– Custom materials
– Flexibility to make tooling modifications
– Ruggedized strain reliefs
Incorporate those nice to have and must have features

9. Manufacturing That Eliminates Risk & Improves Reliability
9
Customization of Features
 Implement design features to pass qualification testing
– Waterproofness
– Radiated / conducted emissions and susceptibility
– Salt fog
 Employ specialty materials, processes
– Fungal resistance jacket
– Encapsulate PCBA, switches, sensors
– LEDs to indicate status
Consider adding passive components and PCBAs to your build plan

10. Manufacturing That Eliminates Risk & Improves Reliability
10
Customization of Features
 Consolidate several discrete cables and components into one solution
– Eliminate daisy chained assemblies
– Add customized features to standard offerings
Hybrid cable assemblies can address various design challenges

11. Manufacturing That Eliminates Risk & Improves Reliability
11
Custom Connectors
 Use 3D modeling to create desired design
– Solidworks, .STP, .IGS, etc.
 Complete control of the design
– Pin engagement
– Customizable overmold
 Add all those design pesky details
– Beryllium copper coating to pins
– Polarity markings
 No EOL or Obsolesce
– Custom tooling is catalogued and
maintained
By owning the tooling, obsolesce can be mitigated.

12. Manufacturing That Eliminates Risk & Improves Reliability
12
Use of Substitute Components
 Custom cable assemblies can be design
with form, fit, function equivalent
connectors
 Mitigate long lead times
 Cost savings
 Important considerations
– Pin count, pitch, size
– Polarization or locking feature
– Interface tolerances
– Footprint
– Electrical rating
– Material compatibility
– EOL or planned obsolescence
– Flammability rating
Replace specialty connectors with form, fit, function equivalents

13. Manufacturing That Eliminates Risk & Improves Reliability
13
Incorporating Tests & Special Processes
 100% Leak Testing
– Install in fixture and test each cable assembly at 3.5 psi
– Pressurize wire jacket and submerge in bath of isopropyl alcohol
 Implement AQL Electrical Testing
– Radiated emissions sweeps
– Continuity testing, hipot testing
Provide value by including additional assembly and processing steps

14. Manufacturing That Eliminates Risk & Improves Reliability
14
Incorporating Tests & Special Processes
 Perform in process mechanical testing
– Flexure, bend, and pull testing
 Follow specialty processes and tests
– ATP Procedure
– Burn in
– Ex. soak in liquid before assembly
Provide value by including additional assembly and processing steps

15. Manufacturing That Eliminates Risk & Improves Reliability
15
How to Get Started With Your Custom Build

16. Manufacturing That Eliminates Risk & Improves Reliability
16
How to Get Started With Your Custom Build
 Visit www.epectec.com/cable-assemblies
 Review website for technical information
 Summarize must have & nice to have requirements
 Understand the application
 Epec can help design your cable
– Drawing creation
– 3D modeling
– Connector down select
– Wire AWG and jacket review
Engage Epec Early - Convert IDEAS into a DESIGN

17. Manufacturing That Eliminates Risk & Improves Reliability
17
How to Get Started With Your Custom Build
 Don’t reinvent the wheel
 Use standard components and
connectors where possible
 House tooling exists for many
standard connector schemes and
sizes
 Avoid lengthy lead-times and MOQs
by selecting common wire wherever
possible
Using standard wire and house tooling can save time and money

18. Manufacturing That Eliminates Risk & Improves Reliability
18
How to Get Started With Your Custom Build
 Understand the project details:
– What is your budget?
– What is your timeline?
– Who has design authority?
– What are the qualification requirements?
Budget and timeline have a tremendous impact on design options

19. Manufacturing That Eliminates Risk & Improves Reliability
19
The Steps to Developing a Custom Cable Assembly
Production samples are required to verify the build plan
Prototype Preliminary Concept ProductionInitial Design

20. Manufacturing That Eliminates Risk & Improves Reliability
20
The Steps to Improving a Custom Cable Assembly
If you own the design, you can make modifications to improve performance
Original Design Leak Test Failure Epec ProductionEpec Solution

21. Manufacturing That Eliminates Risk & Improves Reliability
21
Summary

22. Manufacturing That Eliminates Risk & Improves Reliability
22
Summary
 Use an Off the Shelf Cable for the right projects
 Don’t settle for an inferior cable assembly
 Incorporate those nice to have and must have features
 Engage Epec early - convert IDEAS into a DESIGN

23. Manufacturing That Eliminates Risk & Improves Reliability
23
Our Products
Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards
RF Products User Interfaces Flexible Heaters EC Fans & Motors

24. Manufacturing That Eliminates Risk & Improves Reliability
24
Q&A
 Questions?
– Enter any questions you may have
in the control panel
– If we don’t have time to get to it, we
will reply via email

25. Manufacturing That Eliminates Risk & Improves Reliability
25
Thank You
Check out our website at www.epectec.com.
For more information email sales@epectec.com.
Stay Connected with Epec Engineered Technologies
Follow us on our social media sites for continuous technical updates and information: