Technical Resource

Solid copper cables operate safely at cool temperatures, while CCA (Copper-Clad Aluminum) cables generate dangerous red hot spots due to their higher resistance, visualizing the risk of using CCA in power applications.

The Engineer's Guide to Cable Conductors: Solid...

When designing custom cable assemblies, engineers must balance weight against electrical efficiency by choosing between Solid/Stranded Copper, Pure Aluminum, and Copper-Clad Aluminum (CCA). While pure copper offers the highest conductivity,...

The Engineer's Guide to Cable Conductors: Solid...

When designing custom cable assemblies, engineers must balance weight against electrical efficiency by choosing between Solid/Stranded Copper, Pure Aluminum, and Copper-Clad Aluminum (CCA). While pure copper offers the highest conductivity,...

A technical 3D illustration visualizing the difference between continuity and Hi-Pot testing.

The Engineer's Guide to Cable Testing: Continui...

Continuity testing verifies that electrical current flows from point A to point B through a conductor, confirming correct pinout. However, Hi-Pot (Dielectric Withstand) testing applies a massive high voltage (e.g.,...

The Engineer's Guide to Cable Testing: Continui...

Continuity testing verifies that electrical current flows from point A to point B through a conductor, confirming correct pinout. However, Hi-Pot (Dielectric Withstand) testing applies a massive high voltage (e.g.,...

Professional photograph of an engineering quality control workbench. A custom wire harness is being measured with digital calipers over technical blueprints.

What is a Custom Cable Assembly? Types, Standar...

A cable assembly is a group of individual wires or cables encased in a single, ruggedized outer jacket or overmold, designed to transmit power, data, or signals between devices. Unlike...

What is a Custom Cable Assembly? Types, Standar...

A cable assembly is a group of individual wires or cables encased in a single, ruggedized outer jacket or overmold, designed to transmit power, data, or signals between devices. Unlike...

The tinned copper braided shield is combed and crimped into a ring terminal for grounding, positioned next to the signal wires terminated into a pluggable terminal block.

The Engineer's Guide to Shield Grounding: Singl...

A ground loop occurs in a complex wire harness assembly when a cable shield is grounded at multiple points that have different electrical potentials, causing unwanted EMI/RFI current to flow through...

The Engineer's Guide to Shield Grounding: Singl...

A ground loop occurs in a complex wire harness assembly when a cable shield is grounded at multiple points that have different electrical potentials, causing unwanted EMI/RFI current to flow through...

Wide-angle industrial photograph inside a modern custom cable manufacturing facility showing massive spools of varying AWG wire

The Engineer's Guide to 24V DC Voltage Drop: AW...

Voltage drop in 24V DC systems occurs when the inherent electrical resistance of a long-run wire harness consumes circuit voltage, causing end-point devices like PLCs, sensors, and actuators to underperform...

The Engineer's Guide to 24V DC Voltage Drop: AW...

Voltage drop in 24V DC systems occurs when the inherent electrical resistance of a long-run wire harness consumes circuit voltage, causing end-point devices like PLCs, sensors, and actuators to underperform...

A photograph inside a professional B2B quality control laboratory showing a technician preparing a custom wire harness sample for micro-sectioning.

The Engineer's Guide to Gas-Tight Crimping: Def...

High-resistance crimps occur when thermal cycling degrades a non-gas-tight termination, allowing micro-fretting and oxidation to form between the copper wire strands and the terminal barrel. To prevent voltage drops and...

The Engineer's Guide to Gas-Tight Crimping: Def...

High-resistance crimps occur when thermal cycling degrades a non-gas-tight termination, allowing micro-fretting and oxidation to form between the copper wire strands and the terminal barrel. To prevent voltage drops and...

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