Spend enough time around cable assemblies and you’ll know how common multi-conductor cable assemblies are in industrial equipment and commercial products. We build them all the time: They solve design challenges that individual wires can’t.

Here’s what else we see: Multi-conductor cable assemblies that don’t actually need to be multi-conductor. Some designs function just as well with loose or bundled wire, and those designs save a ton of cost.

Your application requirements will dictate your ideal cable assembly. Let’s go through the key factors in the decision.

Here’s when multi-conductor cable assemblies are the right choice

Put simply, a multi-conductor cable assembly groups multiple conductor wires within a common jacket. That jacket can protect the conductors from environmental conditions, reduce wear during handling or provide shielding when signal integrity is a concern.

Environmental protection

Multi-conductor assemblies are useful when wires will be exposed to water, sunlight or abrasive conditions. The outer jacket helps extend the service life of the assembly.

Without a jacket, individual wires remain susceptible to damage from the operating environment. But in applications where conductors are protected within an enclosure, that added layer of protection may not be needed.

Durability for repeated handling

Cable assemblies that are regularly installed, removed or repositioned experience more wear than stationary wiring. A jacket helps protect the conductors from damage caused by repeated bending and handling.

Applications where wiring remains fixed after installation may not require that added protection.

Improved wire management

Routing individual wires through the same piece of equipment can create unnecessary clutter.

A multi-conductor cable assembly combines those conductors into a single cable, simplifying routing and reducing the space required for wiring.

In applications with ample space and simple routing, individual wires may be easier to work with.

Electrical shielding and signal integrity

Some cable assembly applications need protection from electromagnetic interference. Multi-conductor wiring is often shielded by a conductive layer beneath the outer jacket that intercepts unwanted electrical noise.

Some OEMs specify shielding because it seems like added protection. But shielding provides the most value when it is properly selected, terminated and integrated into the overall electrical design. If a shield is never terminated and the assembly performs as intended, that shielding may be unnecessary.

Here’s where unjacketed wires may be the better option

If an application does not require the protection offered by a multi-conductor cable assembly, unjacketed wires may be the more practical option.

• A foot of wire can cost only a few cents, while multi-conductor cable can cost $2-$3 per foot before processing.
• The outer jacket must be removed before termination.
• Additional processing increases manufacturing time.

Those added costs are often justified when environmental protection, durability or shielding are necessary. When they’re not, a simpler design may achieve the same result at a lower cost.

Determining whether those added costs are justified is where a design for manufacturability partner becomes valuable.

Multi-Tek as a DfM-focused cable assembly partner

A design for manufacturability (DfM) review helps determine whether every component in a cable assembly serves a purpose.

Multi-Tek works with OEMs to evaluate cable assembly designs before production begins. As a DfM-focused cable assembly manufacturer, we identify opportunities to improve manufacturability and reduce sourcing challenges.

That may involve:

• recommending alternative materials that reduce costs
• removing unnecessary shielding requirements
• simplifying designs where appropriate

The result? A cable assembly designed around the actual needs of the application.

Want to talk more about your cable assembly design?

Then let’s do it. We love talking shop. If you’re evaluating whether your cable assembly design requires jacketed multi-conductor cable, get in touch to discuss your application today.