Leading manufacturer of control cables
At Custom Designed Cables, we design and manufacture custom control cables for machinery, automation systems and process equipment across a wide range of industries. Control cables carry the low-voltage signals that tell equipment what to do, linking controllers, sensors, actuators, drives and switchgear so a system operates as intended.
Unlike power cables, which are judged mainly on current-carrying capacity, control cables are judged on signal integrity. A control signal that arrives corrupted, delayed or swamped by electrical noise causes the same problem as no signal at all, which is why construction, screening and routing matter so much in control applications.
With over 20 years’ experience, we manufacture bespoke control cable to order, engineered around the electrical, mechanical and environmental demands of your application.
What is a control cable?
A control cable is a multi-conductor cable used to transmit control signals rather than to supply power to a load. It typically carries several small cross-section cores within a single sheath, often with colour coding or numbering so individual circuits can be identified quickly during installation and fault-finding.
Most control cables include some form of screening. Control circuits frequently run alongside power cables, variable speed drives and motors, all of which generate electromagnetic interference. Without a screen, that interference couples into the control cores and corrupts the signal.
Construction varies considerably by application. A cable running in a fixed panel has very different requirements from one flexing thousands of times a day on a moving axis.
Types of control cable we manufacture
We build control cables in a wide range of constructions to suit different environments and duty cycles.
Screened and unscreened control cables
Screened control cables use foil, braid or a combination screen to protect signals from electromagnetic interference. Unscreened versions suit installations where interference is not a concern and cost or flexibility takes priority. Our cable shielding service covers the full range of screening options.
Flexible control cables
Where a cable moves in service, whether on a drag chain, a robot arm or a moving gantry, construction has to account for repeated flexing. Our flexible cables and robotic cables use fine stranding and specialist lay configurations to survive millions of flex cycles.
Multicore control cables
Multicore cables combine a large number of control circuits into a single solution, simplifying installation and reducing cable management on complex machinery.
Harsh environment control cables
Where cables face oils, coolants, chemicals, abrasion or extreme temperatures, jacket material becomes the critical decision. PUR cables offer excellent abrasion and oil resistance, while high temperature cables and harsh environment cables cover more demanding conditions again.
Applications for control cables
Control cables appear in almost any system where equipment is operated automatically or remotely. Typical applications include:
- Industrial automation and production line control
- Machine tools, CNC equipment and robotics
- Building management systems and HVAC control
- Instrumentation and process measurement
- Medical equipment and diagnostic systems
- Food and beverage processing plant
- Water treatment and utilities infrastructure
- Marine and offshore systems
Custom control cable manufacturing
Standard control cable is widely available, but it forces you to design around the cable rather than the other way round. As a bespoke manufacturer, we build to your specification.
We can customise:
- Core count, conductor size and stranding
- Colour coding, numbering and identification
- Screening configuration and coverage
- Insulation and jacket materials, including LSZH and fire resistant options
- Overall diameter and flexibility
- Armouring and mechanical protection
- Hybrid constructions combining control, power and data in one cable
- Cut lengths, drums and coils
Hybrid constructions are worth particular consideration. Combining control, power and data cores within a single sheath reduces installation time, simplifies routing and cuts down the number of separate cable runs a machine needs.
Why choose Custom Designed Cables?
At Custom Designed Cables, we combine technical expertise with fast, reliable manufacturing to deliver bespoke cable solutions built around your exact requirements.
We offer:
- ISO 9001:2015 quality management
- UL & CSA approved options available on selected product ranges
- Fast turnaround times
- Bespoke cable design and manufacturing
- Access to a comprehensive materials library
- Free technical consultation and support
Frequently asked questions
What are control cables used for?
Control cables transmit signals between controllers, sensors, actuators and equipment, allowing machinery and automated systems to be operated and monitored. They carry control signals rather than supplying power to a load.
What is the difference between a control cable and a power cable?
Power cables are designed to carry current to a load, so conductor size and current capacity are the main considerations. Control cables carry low-voltage signals, so signal integrity, screening and flexibility matter more than current-carrying capacity.
Do control cables need to be screened?
Not always, but frequently. Control circuits often run close to power cables, drives and motors that generate electromagnetic interference, which can corrupt control signals. A screened cable prevents that. Unscreened cable is suitable where interference is not a concern.
What is the best jacket material for control cables?
It depends on the environment. PVC suits general-purpose indoor use, PUR offers strong oil and abrasion resistance for industrial settings, and LSZH is specified where fire safety and smoke emission are a concern. Our team can advise on the right material for your application.
Can control cables be made to a custom specification?
Yes. We manufacture bespoke control cables to order, with control over core count, conductor size, screening, insulation, jacket material, colour coding and overall construction.
Get a quote for your control cables
Looking for custom control cables or advice on the right specification for your application? Contact Custom Designed Cables today to discuss your requirements.
