Manufacturing specialty cables just like specialty boards

[kiyotewolf]

I debated using the general section, but..

I'd love to see you cover this Dave.

You've got a custom project, and it's got all it's inputs and jacks, and whatnot, and it connects to something at the other end, .. piece of equipment, some Joe's computer back panel..

How do you get your custom cable, built to order, with all the strain relief you want, the fancy dongle looking end, where it splits into finer cables, and then off to particular plugs of various kinds?

A working example would be..

::::

Just the other day, I was using a retro computer, TI 994/a, and, my audio interface cable was MIA.

Got the parts, followed the diagram, but on a professional point of view, it's stuff hacked together, held together with tape.

How, where, would I go, to get something, which is not an exact copy or even a duplicate of the original cable, but a new cable, which happens to have the same wiring?

And this example, would be for any project really, not just rebuilding retro computers, with brand new cables from the 80's.



~Paul

This has been bugging me for quite awhile, and I'd love an answer, or even better, a video.

[Short Circuit]

This is quite simple actually; you draw a diagram of the wanted cable assembly. Usually as if laid out on the table with connectors and wiring as if it was a normal schematic. Added to that the wire sizes, lengths of segments, requirements for shielding, drainwires, cable impedance, UL rating, connector partnumbers, probably references to other drawings (such as specific strain relief designs).

Then you find a selection of cable manufacturers (usually China these days) that seem ok, and ask for quotations. You find these on alibaba or globalsources, and browse their online portfolio for similar cable assemblies as what you want to make.

Of course you need to have quite a few to justify this route. Usually, the MOQ is 1000 assemblies or thereabout, and in case of custom raw cable (so the cable is build exactly to your spec), and additional MOQ of 3000 meters or thereabout. But often, it's no biggie to negotiate a somewhat smaller MOQ, especially with first order.

In the attachments is an example of a USB cable assembly that I have in the making at this moment.
Just a simple drawing of the connections, of the desired packing and a custom strain relief (with last page suppliers' drawing of the sr for mould making).
Costs for such a project are $509 for mouldmaking and sample production and  $2.27 each for production of 1000pcs.

[kiyotewolf]

Make a run of TI 994/A cassette interface cables, and sell them till I get old and grey.   


~Paul

Thanks for the info!  Are there, any other ways, of getting smaller runs of custom cables?