Custom Design Cables
Welcome to Insulated Wire – The Home of Custom Cable Solutions
Discover our industry-leading Custom Design Cables, engineered to meet diverse and demanding requirements across multiple sectors.
Our Custom Cable Solutions are meticulously crafted to support specialized needs, offering unmatched quality and performance. With a focus on robust construction and technological innovation, we provide custom wire configurations that enhance connectivity and durability for critical applications.
Our products are designed to excel in harsh environments, ensuring reliability and precision where it matters most.
Since its inception in 1970, Insulated Wire (IW) has been at the forefront of cable technology, specializing in the manufacture of high-performance microwave cable and cable assemblies.
With revolutionary technology like our unique PTFE lamination process and patented shield designs, IW provides robust solutions for a multitude of applications, extending capabilities up to 150 GHz.
Cable Capabilities and Customization
IW’s expertise in cable design allows us to offer an extensive range of custom cable solutions tailored to meet specific customer needs. Our product range includes:
- Custom Twisted Pairs and Tripe Wire: Essential for data transfer and communication applications.
- Custom Impedance RF Cables: Available in flexible and semi-rigid configurations to suit varying application demands.
- Composite Cables: Featuring fiber and coaxial options, perfect for environments requiring robust performance under extreme conditions such as hydrostatic pressure, UV exposure, and more.
- Specialty Cables: Designed to withstand severe environmental conditions including Nuclear & Biological Conditions (NBC), submarine deployments, and space flight.
State-of-the-Art Manufacturing and Testing Facilities
Located in Bayport, NY, with an additional facility in Ronkonkoma, NY, our operations are both AS9100 and ISO9001 certified, ensuring top-quality production and reliability. Our capabilities include:
- Environmental Testing: Humidity, salt spray, vibration, and thermal shock testing to ensure durability.
- Advanced Technical Services: Offering engineering support for optimal cable/connector configurations in complex systems.
- Custom Assembly Configurations: We accommodate unique assembly needs and can extrude a broad range of jacketing materials, from FEP to Low Smoke/Zero Halogen TPU.
Innovative Products and Specifications
Our cable specifications are designed to meet the rigorous demands of both military and commercial applications. Highlights include:
- Low Loss/Phase Stable Coax: Specialized for high-frequency operation up to 110 GHz.
- Re-Flex™ Hand-Formable Coax, High Performance 75Ω and Semi Rigid Cables: Offers flexibility with high-end performance.
- Extensive Product Range: Cable diameters ranging from 0.034″ to 0.750″, supporting applications from basic wiring to complex multi-conductor cables.
Mechanical Construction
IW’s composite cables provide a myriad of options. Components can include individually shielded and jacketed signal transmission cables, power cables, microwave cables and fiber optic.
Depending on the application, cables can be optimized to address issues such as hydrostatic pressure, tensile loads, concentrated compression points, etc. Overall shielding can be provided with ferrous or nonferrous
materials.
High performance, non-metallic braids and strength members, such as Kevlar™ are also available.
Markets and Applications
IW’s custom cables serve a diverse range of sectors including aerospace, military, telecommunications, medical electronics, and geothermal exploration. Each cable is crafted to handle the specific challenges of its application, ensuring optimal performance under the most demanding conditions.
Application Example
One example is a multiconductor assembly used on a submarine application which includes twisted pair, twisted triple, 16AWG and custom coaxial cable. The bulk cable is manufactured at Insulated Wire’s Long Island, NY facility with the coaxial connectors and cable assemblies prepared at IW MicrowaveProducts Division facility in Bethel, CT.
The cable was produced for a submarine application and contains multiple, individual signal cables and IW’s Tuf-Flex™ microwave cables for use at frequencies up to 18 GHz.
Water block fillers and binders are incorporated under a double braided Sn/Cu braid and polyurethane jacket. Cable withstands the anticipated environmental extremes in accordance with the method requirements of MIL-DTL- 24643B par 4.8.8 and can withstand hydrostatic pressure up to 1050 psi.
