At Custom Designed Cables, cable design is not just about construction. It’s an engineered process that ensures electrical performance, mechanical durability, regulatory compliance and long-term reliability in everything from industrial automation and power distribution to high-speed data transmission and medical equipment.
This guide explains the full design process and how our specialist team turns complex requirements into high-performance custom cable solutions.
What is a cable design?
Cable design is the engineering process of specifying and configuring a cable to meet defined electrical, mechanical and environmental requirements while ensuring conductivity, signal integrity, safety and long-term reliability.
A professionally engineered cable design includes:
- Conductor material and sizing
- Insulation type and thickness
- Shielding configuration
- Mechanical reinforcement
- Outer jacket material
- Compliance with industry standards
Types of cables we design
We design cables for a wide range of applications, including:
1. Power cables
Used to transmit electrical power, power cables can range from low voltage for household wiring to high voltage, like those found in transmission lines. Power cables typically consist of conductors, insulation and protective sheathing.
2. Data cables
Designed for transmitting data signals, data cables include many specialistic cables such as Ethernet cables, coaxial cables and fibre optic cables. They are used across a wide variety of applications, including networking, telecommunications and internet connections.
3. Control cables
Control cables transmit signals in industrial machinery and automation systems. These cables typically feature multiple conductors and are designed with durability and flexibility in mind.
4. Instrumentation cables
Used in process control and instrumentation systems, instrumentation cables carry signals from sensors and instruments, often using bespoke shielding to prevent electromagnetic interference.
5. Flexible cables
Flexible cables are built for applications involving frequent movement or bending, such as robotics, automotive systems and portable devices. They feature special insulation and construction to withstand repeated flexing without causing damage.
6. High-temperature cables
High-temperature cables are built to operate in extreme temperatures, both high and low, without performance degradation or safety risks. This type of cable is often in environments like aerospace, military applications or industrial furnaces.
7. Ribbon cables
Consisting of multiple parallel conductors, ribbon cables are designed to be used for internal connections. These cables are often found in electronic devices and computers, providing them with a compact and organised solution for cable management.
The cable design process
Our structured engineering process ensures every requirement is addressed:
Step 1: Application & specification analysis
Every cable design begins with a detailed consultation. We assess:
- Voltage and current ratings
- Signal type and frequency
- Flexing requirements
- Tensile load expectations
- Environmental exposure (temperature, moisture, chemicals, UV)
- Installation method
This stage defines the cable’s electrical and mechanical performance envelope.
Step 2: Conductor selection
Choosing the correct conductor material is critical. Common options include:
- Copper – excellent conductivity and flexibility
- Aluminium – lightweight and cost-effective
- Optical fibre – high-bandwidth, low-loss data transmission
We calculate conductor gauge based on ampacity, voltage drop and thermal limits to ensure safe operation.
Step 3: Insulation design
Wire insulation prevents electrical faults and protects against environmental exposure. Material options include:
- PVC (cost-effective and versatile)
- Polyethylene (excellent dielectric properties)
- Rubber or silicone (flexible, high-temperature performance)
Thickness is precisely calculated to balance flexibility with protection and regulatory compliance.
Step 4: Shielding & EMI protection
Cable shielding is designed to protect against electromagnetic interference (EMI) and crosstalk. The different types of shielding include:
- Foil shield: A thin layer of aluminium, effective for high-frequency interference.
- Braided shield: Made with woven mesh of copper or aluminium, providing low-frequency EMI protection and mechanical strength.
- Combination shield: Both foil and braided shields used together, designed for comprehensive protection.
The designer then determines the required shielding coverage based on the application’s EMI susceptibility.
Step 5: Jacket & mechanical protection
The cable jacket (outer sheath) protects against physical damage and environmental exposure. Cable jackets are commonly made with:
- PVC: A common and cost-effective solution for many applications.
- TPE (Thermoplastic Elastomer): Offers flexibility and resistance to chemicals and abrasion.
- Polyurethane: Known for its high durability and resistance to both oil and mechanical wear.
Jackets can also include features such as flame retardancy, UV resistance and colour coding for identification and cable management.
Step 6: Prototyping & testing
Before full production, prototype cables undergo comprehensive testing. These tests include:
- Electrical testing: Verifies resistance, capacitance and signal integrity.
- Mechanical testing: Evaluates strength, flexibility and durability.
- Environmental testing: Confirms resistance to temperature, moisture and chemicals.
Step 7: Documentation & manufacturing integration
Once validated, the final cable design includes:
- Technical drawings
- Full material specifications
- Compliance documentation
- Quality control procedures
This documentation supports consistent manufacturing and traceability – critical for regulated industries.
Benefits of professional cable design
Professional cable engineering provides several key benefits:
1. Enhanced performance
Professional cable design improves conductivity, signal integrity and efficiency through correct conductor materials, insulation thickness and shielding. This reduces power loss, minimises interference and supports consistent performance across the cable’s full operating lifespan, even in demanding environments.
2. Increased safety
Correct cable engineering significantly improves safety by ensuring appropriate insulation, thermal ratings and mechanical protection are applied from the outset. This reduces the risk of electrical shorts, overheating, fire hazards and premature failure, helping to protect both equipment and end users.
3. Cost efficiency
Although bespoke cable design may have a higher upfront cost, it delivers lower total lifecycle costs. Durable materials, accurate specification and robust construction extend service life, reduce maintenance requirements and minimise unplanned downtime, leading to long-term cost savings.
4. Industry compliance
Professionally designed cables are engineered to meet recognised industry and regulatory standards, including ISO, UL, CSA and application-specific requirements. Compliance is built into the design stage, reducing delays, redesigns and certification risks later in the project.
5. Environmental responsibility
Thoughtful cable design supports sustainability goals through efficient material usage, improved energy performance and longer product lifespans. Selecting recyclable or low-impact materials where possible also helps reduce waste and environmental impact over time.
6. Competitive advantage
Custom-engineered cable designs consistently outperform generic, off-the-shelf alternatives. By tailoring performance, durability and compliance to the exact application, organisations gain more reliable systems, improved efficiency and a stronger competitive position in their market.
Challenges of cable design and how we solve them
Cable design requires balancing performance, cost and regulatory compliance. Each project presents challenges that must be addressed early to avoid manufacturing or installation issues.
Common cable engineering challenges include:
- Managing material costs whilst maintaining performance and durability
- Achieving compliance with evolving industry standards and regulations
- Designing for harsh or variable environments, such as extreme temperatures, chemicals or mechanical stress
- Integrating new technologies, including high-speed data transmission or smart monitoring capabilities
- Ensuring ease of installation, particularly in confined or complex routing conditions
Our engineering team mitigates these risks through early-stage technical consultation, detailed specification reviews and real-world prototyping. Every cable design is validated through rigorous testing and supported by robust quality management systems, ensuring reliability, compliance and consistent manufacturing outcomes.
Looking to explore custom cable design and manufacturing? Contact our expert team today, or find more resources on our blog.