How Multi-Conductor Cables Are Manufactured

Multi-conductor cables are the wiring solution of choice across a multitude of industries and applications for their efficiency, reliability, and cost-effectiveness. 

Whether you’re building your own products or taking the lead on an electrical project, having an understanding of how multi-conductor cables are manufactured can help you source the right solution and make the most of all these cables have to offer. 

We’ll walk you through the traditional manufacturing process below, from raw materials and assembly to testing and quality assurance. More importantly, though, we’ll show you how we do things a bit differently than other manufacturers here at AudioVideoElectric.com with our Belden equals.

Our multi-conductor cable manufacturing process leads to a dependable wiring solution at a fraction of the cost of traditional cables from leading brands. In fact, you can get a product that’s identical in form and fit for 20% less! Shop now and source smarter, or learn about how multi-conductor cables are manufactured below.

Overview of Multi-Conductor Cables

Let’s start with the basics, what is a multi-conductor cable? These are a unique wiring solution that consists of multiple insulated conductors enclosed within a common jacket. This streamlines complex wiring configurations, saving stress and money. 

As a result, these are used to transmit signals, power, or data across a wide variety of industries - from automation and telecommunications to simple household consumer electronics.

There are many different multi-conductor cable types. They can have anywhere from two to several dozen conductors. Each is individually insulated, preventing interference and ensuring clear signal transmission. 

You’ll also come across different types of insulation on these cables, including PVC (polyvinyl chloride), Teflon, and rubber, each offering distinct advantages such as flexibility, heat resistance, and chemical stability. It’s just a matter of aligning with the specific requirements of your project.

Shielding options, like foil or braided shields, are often incorporated to protect against electromagnetic interference (EMI) and crosstalk, supporting superior signal integrity.

All of these unique characteristics lead to several advantages of multi-conductor cables. The most important is the organized and efficient transmission of multiple signals or power sources in one cable. This reduces clutter, simplifies installation, and enhances system reliability. 

The protective jacket also offers mechanical protection and environmental resistance, extending the cable's lifespan and offering better reliability in harsh conditions.

You can learn more about the differences between a single conductor vs multi-conductor cable in our blog if you’re interested. Otherwise, let’s get into the manufacturing process for these cables.

How Multi-Conductor Cables Are Manufactured

Whether you’re simply curious about how multi-conductor cables are manufactured or you’re looking to learn about nuances in different types of cables, we’ll walk you through the most important steps in bringing these cables to life.

Raw Materials and Components

It all starts with sourcing quality materials - with copper being the most common for its electrical conductivity and flexibility. Applications that need higher strength or specific performance characteristics may choose aluminum or other alloys instead. 

Insulation materials such as PVC, polyethylene, or Teflon are chosen based on the cable’s intended use, considering factors like temperature resistance, flexibility, and environmental protection. 

Other components like fillers, shields, and jacketing materials are also selected to meet specific design requirements. We’ll speak to each of these at some point below as we walk you through actually manufacturing the cables.

Stranding and Conductor Assembly

The first step in the manufacturing process is stranding, where individual copper or aluminum wires are twisted together to form a single conductor. 

Stranding improves the cable's flexibility and durability. The number of strands and their configuration (concentric, bunched, or rope-lay) depend on the desired mechanical and electrical properties.

The conductors are assembled into the required configuration after the stranding process. This involves grouping multiple conductors together in a specific arrangement, which can be parallel, twisted pair, or bundled, depending on the cable’s design specifications. Fillers are often added during this stage to maintain the cable's shape and prevent the conductors from shifting.

Insulation Process

Each conductor is then coated with an insulating material to prevent electrical shorts and ensure signal integrity. 

The insulation process involves extruding the chosen material, such as PVC or Teflon, over the conductor. This is done using high-temperature extrusion machines that evenly apply the insulation to form a uniform layer around each wire. 

The thickness of the insulation is carefully controlled to meet industry standards and specific application requirements. 

Jacketing

After the conductors are insulated, they are bundled together and encased in a protective outer jacket. This is somewhat similar to the insulation process. 

This outer jacket serves multiple purposes: it provides mechanical protection against physical damage, environmental protection against moisture and chemicals, and additional electrical insulation. 

Depending on the cable’s application, the jacket may also include special features such as UV resistance or flame retardancy.

Testing and Quality Assurance

Before the products are actually sent to market, they’re carefully tested to ensure they function properly. Quality assurance looks at electrical, mechanical, and environmental specifications. Tests include measuring electrical conductivity, insulation resistance, and capacitance to verify performance. 

Mechanical tests assess the cable’s flexibility, tensile strength, and resistance to abrasion and impact. Environmental tests expose the cable to extreme conditions, such as high and low temperatures, humidity, and chemical exposure, to ensure durability and reliability.

Advanced testing equipment and techniques, such as automated inspection systems and high-voltage testing, are used to detect any defects or inconsistencies. Any cable that fails to meet the stringent quality standards is rejected or reworked to ensure only the highest quality products reach the market. 

At least, that’s the goal - not all manufacturing processes are put under the same strict guidelines. That’s just one of the many differences between our cables and the rest. Let’s talk about how we do things a bit differently here at AudioVideoElectric.com.

We Do Things a Bit Differently Here at AudioVideoElectric.com…

Our approach to manufacturing multi-conductor cables sets us apart, as we have a selection of cables that are identical in fit and form to their branded counterparts but at a fraction of the cost. Learn how we do it below!

The Problems With the Multi-Conductor Manufacturing Process

Even with the innovations of the multi-conductor cable manufacturing process over the years, there are still a few issues that continue to plague customers:

• Inconsistent Quality: Variability in raw materials and manufacturing processes can lead to inconsistency that leads to signal loss, interference, and reduced durability.
• Limited Customization: Many manufacturers offer limited customization options, forcing you to settle for off-the-shelf solutions that may not meet your specific needs.

• Expensive Costs: There seems to be a tradeoff between price and quality with traditional multi-conductor cables. Reliable, efficient solutions can cut into your profits and may not be feasible for certain applications on a tight budget. 
• Insufficient Testing: Some manufacturers cut corners on testing, leading to cables that do not meet rigorous industry standards, which can result in premature failures and safety concerns.

The good news? All of this can be avoided here at AudioVideoElectric.com!

How Our Belden Alternative Cables are Transforming the Industry

We’ve come to be known as the premier provider of multi-conductor cables by creating our own Belden alternative cables that match the specifications and appearance of their branded counterparts. 

However, we offer ours at 10-20% less without any sacrifice in quality. Here are the most common categories we offer:

• multi-conductor cable 16 AWG
• multi-conductor cable 22 AWG
• multi-conductor cable 18 AWG
• multi-conductor cable 12 AWG
• multi-conductor cable 14 AWG
• 20 AWG multi-conductor cable
• 28 AWG multi-conductor cable

These have saved customers as much as 60% on their production costs, translating to savings of more than $86,000 annually for one company. Others have cut $30,000 from their budget while putting stocking challenges in the past for good. Learn more about some of our proudest success stories here.

We may even be able to help you design and manufacture custom cable solutions tailored to your specific needs. This includes selecting the right materials, conductor configurations, and insulation types to optimize performance and reliability.

That being said, we encourage you to reach out today to learn more about what separates our cable manufacturing process from the rest and what it means for you as you seek to create your own products or power your projects. Smarter cable sourcing is just a click away!

Final Thoughts on How Multi-Conductor Cables Are Manufactured

We hope this overview of how multi-conductor cables are manufactured has shed light on the process, from raw material sourcing to stranding, insulating, jacketing, quality control, and more. Each step plays a role in ensuring reliability and efficiency in your electrical setups.

However, the traditional manufacturing process leads to inconsistent quality, lack of customization, and excessive costs. That’s why we decided to change things with our own cable manufacturing process here at AudioVideoElectric.com.

You can learn more about how to strip multi-conductor cable or how to calculate conduit fill for multi-conductor cable in our blog if you still need help choosing the right wiring solution. Otherwise, it’s time you got in touch or browsed our catalog to find the ideal cables for your unique needs today. See what keeps our customers coming back for more by sourcing smarter today!