Leading manufacturer of custom cables
Custom Designed Cables are specialist manufacturers of custom cables, serving customers across the UK and internationally. With more than 20 years’ experience and over 6,000 unique designs to date, we provide tailored solutions where off-the-shelf cable types simply will not suffice.
A custom cable might involve something as straightforward as an alternative jacket colour or Low Smoke Zero Halogen (LSZH) version of an existing type. At the other end of the scale, it could mean a highly complex construction combining multiple elements to meet stringent technical or regulatory demands.
Whatever your requirement, our team designs and builds every cable in the UK, under ISO 9001:2015 certification, with UL and CSA approvals where applicable.
What is a custom cable?
A custom cable is designed and manufactured for a specific application. Standard catalogue cables may meet general needs, but specialised projects often demand cables that perform reliably in unusual conditions or integrate multiple functions into a single product.
Examples include:
- A cable jacketed in a PUR (polyurethane) compound for exceptional abrasion resistance.
- Colour-coded conductors arranged to suit a control panel or harness.
- A hybrid design combining data, power, and video in one construction.
These products are built to order, using materials and shielding configurations matched to the intended operating environment.
When to choose a custom cable over a standard type
Sometimes a catalogue product works. But when the environment or specification demands more, a custom build is the right choice.
Harsh operating environments
If a project involves extreme temperatures, constant movement, or exposure to oils and abrasion, a custom build ensures the cable will last. Materials such as PUR, XLPE, or nylon can provide extra durability and performance compared to standard PVC.
Hybrid requirements
Some applications demand multiple functions in a single run. A hybrid cable might combine power, data, and video conductors in one jacket, saving both space and installation time. These designs also reduce points of failure compared with running multiple separate cables.
Compliance obligations
In regulated industries, the right materials and approvals are essential. We build LSZH, flame-retardant, and mica-taped designs to meet national and sector-specific requirements, ensuring safety and regulatory acceptance.
Space and weight constraints
Where every millimetre matters, such as aerospace and robotics, custom cables allow compact yet efficient designs. By tailoring conductor sizes and insulation types, we can create a lightweight solution that still meets performance standards.
Industries we serve
Custom cables are used across almost every regulated sector. Below are some of the industries where our designs add the most value.
Aerospace
Aircraft and avionics systems require cables that are lightweight yet tough, with flame-retardant jackets and stable performance under vibration. Our aerospace cables are designed with these critical factors in mind.
Medical
From imaging equipment to surgical tools, medical devices demand precision and safety. We supply cables with biocompatible materials and precise shielding to ensure consistent and interference-free operation.
Defence and military
Defence projects often face harsh climates and rugged conditions. We manufacture cables that withstand shock, vibration, and rapid deployment environments while meeting strict military specifications.
Nuclear and energy
Nuclear facilities and power plants call for radiation-resistant insulation and rigorous documentation. Our cables are built with materials and records that satisfy even the most demanding compliance requirements.
Automotive and transport
Control systems, infotainment, and safety features in vehicles all rely on durable cabling. Our automotive custom cables are designed for reliability under heat, vibration, and long-term wear.
Our team works directly with engineers and procurement specialists to ensure every specification is achievable, practical, and cost-effective.
Design and manufacturing process
Every project begins with a consultation to understand your technical, environmental, and compliance needs. From there, we:
- Define requirements – performance, jacket type, conductor size, shielding, temperature range.
- Develop a design – either from first principles or by modifying an existing cable type.
- Prototype and test – low minimum order quantities are available, ideal for trial builds.
- Move to production – with typical lead times of just 7–10 days, subject to material availability.
This structured process ensures your custom cable moves quickly from concept to delivery.
Material and construction options
The right choice of jacket, shielding, and conductor arrangement makes the difference between acceptable performance and long-term reliability.
Jackets and insulation
We manufacture cables with a wide range of jackets, including PVC, LSZH/LSOH/LSF, PUR/TPU, Hytrel/TPE, Santoprene/TPV, nylon (PA11/PA12), XLPE, XLPO, PE, and PP. Each material offers different properties for temperature resistance, mechanical strength, and environmental safety.
Shielding
To protect against interference, we provide lapped screens, and braided shields. These are available in plain copper, tinned copper, oxygen-free copper, or silver-plated copper, allowing you to balance performance and cost. This ensures reliable protection against electromagnetic interference in demanding environments.
Conductor arrangements
We can build twisted pairs, triples, quads, or bunches of up to 180 individual cores in varying configurations. This flexibility ensures that both simple and highly complex designs are possible. Conductor sizing can also be tailored to suit specific current-carrying and space requirements.
Tapes
Where additional protection is required, we use tapes such as aluminium foil with drain wires, fire-resistant mica glass, polyethylene, polyester (Melinex/Mylar), water-blocking, and non-woven polyester tapes. Each tape type is selected to match the cable’s mechanical and environmental protection requirements.
These combinations allow us to match electrical, mechanical, and environmental performance to the exact demands of your project.
Compliance and quality assurance
All products are manufactured in accordance with recognised British, European, and international standards. Our facility holds:
- ISO 9001:2015 certification.
- UL and CSA approvals where required.
- Compliance with RoHS and REACH directives.
- Full material traceability and documentation for every component used.
This guarantees that every custom cable we supply can be relied upon for safety, performance, and regulatory acceptance.
Custom cable assemblies
In addition to standalone cables, we manufacture custom cable assemblies for specific applications.
These include:
- Custom power supply cables for energy and industrial systems.
- Custom aircraft cable assemblies for avionics, ground systems, and control panels.
- Automotive custom stainless steel cable assemblies for performance and safety-critical uses.
- Control cable assemblies tailored for automation and machinery.
Assemblies are built to your drawings or co-developed with our engineers, offering ready-to-install solutions.
Why choose Custom Designed Cables?
Over the past two decades, we have supported clients ranging from small prototype developers to large international OEMs. Choosing CDC means:
- UK manufacturing with fast turnaround times.
- Over 6,000 unique designs successfully delivered.
- Low minimum order quantities, ideal for prototyping and small runs.
- Speed of delivery – typical lead times of 7–10 days.
- Technical support from experienced engineers.
- Consistent quality backed by ISO 9001:2015 and UL/CSA approvals.
Our goal is to make the process as straightforward as possible while delivering reliable, cost-effective custom cables tailored to your needs.
Frequently asked questions
What is the minimum order quantity for custom cables?
We can manufacture both small and large production runs. For development and prototyping, our low minimum order quantities make it possible to trial a design before committing to higher volumes. This flexibility helps reduce risk and cost while still achieving a fully certified build.
How long does it take to manufacture a custom cable?
Lead times typically range from 7–10 working days, depending on material availability and project scope. Because all production takes place in the UK, we can respond quickly to urgent requirements. For complex designs or large runs, we’ll provide an estimated delivery schedule during consultation.
Can you design hybrid cables that combine power and data?
Yes. Hybrid custom cables are one of our most common requests. We can combine data, control, video, and power conductors into a single construction, saving space and reducing installation time. Each hybrid design is tailored to your application and can include shielding, jacketing, and compliance requirements.
Do you provide custom cable assemblies for aerospace and automotive?
We design and build custom cable assemblies across multiple sectors, including aerospace, defence, automotive, and industrial control. Assemblies can be produced to your drawing or co-developed with our engineers. All assemblies are manufactured in the UK under ISO 9001:2015, with full material traceability and supporting documentation.
Are your cables compliant with international standards?
Yes. All products are manufactured under ISO 9001:2015 and can be supplied with UL and CSA approvals where required. Compliance with RoHS and REACH directives is standard. This ensures that every cable is safe, environmentally responsible, and accepted across regulated industries in the UK and internationally.
Get a quote for your custom cable
Not sure which specification fits your project? Contact us for a free consultation with our technical team.
Send us your drawing or requirements today and we will provide a fast, clear quotation for your custom cable needs.
