What is Custom Cable Manufacturing?

Custom Cable Manufacturing involves combinations of connectors, terminals, and cable systems that are used in electrical power devices to transmit data or electrical signals.

Specifications and requirements for custom cable manufacturing and production:

  • Appearance requirements

After the cable is processed, the rubber should be uniform and smooth. Pores, cracks, indentations, depressions, breakage, spots, dirt, or other similar imperfections are unacceptable.

The cable and connector are firmly pressed together without spaces. If welded together, they should be firm and the core should not be loose.

  • Technical requirements

The insulator should be tightly packed around the conductor but should be easy to peel off without damaging the insulator itself and the conductor. The insulator’s surface should be even and of uniform color and luster.

The average insulator thickness should not be less than the specified nominal value. The width of its thinnest point should be no less than 90% or 0.1 mm of the nominal value.

The insulator core should withstand an AC 50Hz spark test on the intermediate check.

  • Color of the insulated wire core

The insulator wire core should be easy to identify through properly coded colors. These colors should not fade easily. The cables should also be properly marked. If other identification methods are used, they should fall within international product standards.

The colors should be as follows:
single-core cables: no preferred color.
two-core cables: no preferred color.
three-core cables: green/yellow, light blue, and brown; or light blue, black, and brown.
four-core cables: green/yellow, light blue, black, and brown; or light blue, black, and brown.
five-core cables: green/yellow, light blue, black, and brown; or light blue, black, and brown.
Green/yellow is the core color of the ground cable. Neither green nor yellow is allowed for other cores when green/yellow is used in the insulated wire of the cable.

  • Sheathing

The sheath should be tightly packed on the stranded insulated wire core or the inner sheath. It should be easily strippable without damaging the insulator or the inner sheath. The surface of the sheath should be flat and uniform in color or luster. The average thickness of the jacket should not be less than the specified nominal value. The width of the thinnest point should not be less than 85% (or 0.1 mm) of the nominal value.

  • Mechanical Strength

The connector should be able to withstand the mechanical stresses that may occur during normal use. It should be able to pass tensile strength test inspection whether it is required or not.

The required pulling force is applied for 1 full minute. Explosive force should not be used when applying pulling force. The said pulling force can be applied through a tensile strength test machine. The moving speed of the head of the testing machine should be between 25 mm or 1.0 in per minute and 50 mm or 2.0 in per minute. There should be no falling off and no fracture during the test.

The cable will be subjected to a combustion test. After which, the flame on the surface of the specimen should extinguish itself. Also, the distance between the burnt part and the lower edge of the fixture on the test device should not be over 50 mm.

The cable and the insulated wire cores between multiple-core cables should be able to withstand the AC 50Hz non-immersion voltage test.

  • Insulation resistance

The insulation resistance of a cable will be tested to a specified voltage on the insulation core.

  • The electric resistance of the conductor

The following voltage is applied between the cable and the conductors. It is also applied between all the connected conductors and to the sheath:

  1. weak cable: 1500V AC for 1 minute
  2. strong cable: 2000V AC for 1 minute
  3. sheath: 3750V AC for 1 minute.

Applying these voltages will not cause breakdown or flashover.

  • Quality of connector appearance on the manufactured custom cable
  1. The surface of the connector should look good and should be free of scratches, burrs, deformation, poor electroplating, and such.
  2. The riveted joint should not be damaged, loose, or falling off.
  • Wire gauge

The AWG wire gauges maybe 24, 26, 28, or other requested gauges according to the overcurrent requirements of the equipment.


Custom cable systems are built with the specific purpose of withstanding rugged and harsh conditions while delivering flawless data, signal, or power.

Custom-designed and built cable systems by INTE-AUTO are user-friendly and of top quality. They are required to be tough, rigid, and versatile because they are used by different sectors like the medicine, energy, communications, and broadcasting industries.

For more details, please do not hesitate to contact the INTE-AUTO team.

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