Leading Cable Manufacturer in the UK
As one of the UK’s leading cable manufacturers, Custom Designed Cables (CDC) have been designing and manufacturing high-quality cables for over 20 years. Every product we deliver is the result of expert craftsmanship, advanced equipment, and rigorous quality control.
Our engineers oversee every stage of the cable manufacturing process, from initial design and material selection through to final testing and delivery. Each cable we produce meets strict national and international standards, including ISO 9001:2015, UL, and CSA certifications.
With over 6,000 unique cable designs completed and growing technical capability, we manufacture products that perform reliably in demanding environments across multiple industries.
How cables are manufactured
At CDC, we manufacture cables from first principles, starting with bare conductors and building each layer for performance, safety, and durability. Our facility combines high-speed twisting machinery, extrusion systems, and precision taping lines to create both standard and custom constructions.
We also integrate pre-existing products within new cable designs when appropriate to reduce turnaround times and improve cost efficiency, without compromising quality.
Cable twisting and stranding capabilities
We offer four main twisting and stranding methods to match the requirements of each cable design:
1. High-speed twisting machines
Used for smaller twisted pairs, triples, and multicore bunches up to 7.5mm in diameter.
2. High-speed quadding machines
Designed for up to four cores with a maximum finished diameter of 10mm.
3. Single twist machines
Suitable for multicore cables with a maximum twisted diameter of 20mm.
4. Planetary stranding machines
Used for larger cables up to 12 cores, with a finished outer diameter of approximately 40mm.
All machines can apply polyester melinex (mylar) tapes, non-woven polyester tapes, aluminium foil shields with drain strands, fire-resistant (MICA) tapes, and water-blocking tapes (WBT) during the twisting process, helping to reduce costs and improve manufacturing efficiency.
We can also accommodate high-core-count cables (up to 180 cores) using any combination of pairs, triples, quads, or multicore bunches, ensuring a circular and stable final construction.
Our manufacturing process includes:
- Selection and preparation of copper conductors and wire configurations
- Application of insulation materials such as PVC, Polyethylene, or Silicone Rubber
- Precision twisting, taping, and shielding using advanced machinery
- Extrusion of outer sheaths to protect against heat, moisture, and mechanical stress
- Rigorous testing and quality control to verify electrical and mechanical integrity
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Specialist cable manufacturing features
Our cable manufacturing capability allows for:
- Any combination of cores or functions
- In-house or pre-sourced components for efficiency and speed
- Twisted pairs/triples/quad constructions to achieve compact designs
- Core numbering or text printing for easy identification
- Individual or collective shields (foil or braid)
- Cable twisting up to 40mm in diameter
- Application of fire-resistant, water-blocking, or polyester tapes during production
- A wide selection of cable extrusion materials for varied operating environments
- Custom cable printing on outer jackets for branding and traceability
We also provide cable twisting-only services, allowing customers to specify lay direction, lay length (10mm to 500mm), and shielding requirements.
Commitment to quality and customer service at CDC
Quality and communication sit at the heart of everything we do. Our technicians conduct full continuity, insulation resistance, and mechanical testing to ensure compliance with industry standards.
We maintain consistent contact with customers from design approval through delivery to guarantee precision, transparency, and on-time completion. Whether you require rapid prototyping, high-volume production, or specialist designs, our customer service and fast turnaround set us apart from other UK cable manufacturers.
Why choose Custom Designed Cables
- Over 20 years of UK-based cable manufacturing expertise
- More than 6,000 bespoke designs produced
- ISO 9001:2015 certified facility
- UL and CSA approved product ranges
- Rapid turnaround and transparent lead times
- Full material traceability and documentation
- Access to an extensive network of cable distributors and suppliers
- Free consultation and technical support
Whether you’re developing a prototype, sourcing a replacement, or scaling production, CDC can deliver a reliable solution. Get in touch today to discuss your cable manufacturing requirements.
Our other services
Prototype Cables
Cable Printing
Cable Shielding
Want to know more? Call CDC on 01204 658784 or contact us online to discuss your cabling requirements.