Custom Cable Assemblies and Cable Lanyards

There are many things to consider when it comes to designing the most effective cable assembly or cable lanyard for your application. First of all, what type of load will the cable assembly be subject to? Is it tension, compression, static, or dynamic?

Next, one must figure out the work load, shock load (if any), safety factor, and durability considering the environment. For the cable selection, it is important to consider the construction, the diameter, and whether it should be bare or coated. The type of fittings and terminals need to be initially selected and then we will determine whether standard or custom fittings are required.

Finally, one needs to decide whether the tolerance conditions should be tight, normal or relaxed. By considering these mentioned factors, the results of your custom cable assembly or cable lanyard will be as efficient and effective as possible.

Safety Factor Ratios

Ratios to Determine Min. Safety Factors Min. Breaking Strength of Cable : Maximum Working
Normal Conditions 5 :1
Shock or Peak Load Conditions 8:1
Critical or Safety Conditions 10:1

Specifying Custom Cable Assemblies / Cable Lanyard

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Cable Lanyard Tolerances

Assembly Length Tight Tolerance Normal Tolerance Relaxed Tolerance
0-2 ft .030 in /.76 mm .060 in / 1.52 mm .125 in / 3.18 mm
2-5 ft .060 in /1.52 mm .125 in /3.18 mm .188 in /4.8 mm
5-10 ft .108 in /4.8 mm .375 in /9.53 mm .500 in /12.7 mm
10-20 ft .375 in /9.53 mm .500 in /12.7 mm .750 in /19.0 mm
20-40 ft .500 in /12.7 mm .750 in /19.0 mm 1.00 in /25.4 mm
40-50 ft .750 in /19.0 mm 1.00 in /25.4 mm 2.00 in /50.8 mm
Greater than 50 ft Contact MCT Engineering