Customized Aerospace & Defense
Custom Bulk Cable
Specializing in custom bulk cable solutions that meet exact requirements, providing cost-effective options for cable lengths ranging from 1 to 10,000+ feet. With a wide range of wire and component cables to choose from, including military specs, industry standards, or proprietary materials, trust is earned by delivering tailored cable solutions.
Nortech’s Custom Bulk Cable range offers advanced customization, meeting the needs of demanding sectors. Specialized for the electronics and aerospace industries, these cables meet industry standards, military specifications, and proprietary requirements. Designed for durability, they incorporate EMI and EMP protection and can be ordered in any length, without minimum purchase restrictions. The selection includes cables from 32 AWG to 4/0 AWG, complying with prestigious standards like SAE and MIL-DTL series, ANSI/NEMA, and vendor proprietary materials. Quality is ensured through industry-tested materials.
Custom Bulk Cable Advantages
Nortech produces custom bulk cable to your exacting needs. We economically produce cable from 1 to 10,000 feet or more. With Nortech, there is no minimum buy for bulk cable layup and lead time is minimized. Flexibility, flex life, EMI protection, EMP protection, ruggedness, and environmental compatibility is all customizable.
Nortech can incorporate any kind of wire or component cable into a finished cable. Component cable can be military specification, industry standard, or vendor proprietary materials. Sizes typically range from 32 AWG to 4/0 AWG.
Typical materials used include:
- SAE AS22759
- SAE AS81044
- MIL-DTL-17 or RG Type
- ANSI/NEMA WC27500
- ANSI/NEMA HP3, HP4, and HP6
- A-A-59551 (QQ-W-343)
- SAE AS50861
- Boeing Material Specification (BMS)
- Vendor proprietary such a Tyco, Belden, Draka, etc.
…And many others
Custom Bulk Cable Capabilities
A&D Cable Layup Capabilities
Nortech utilizes equipment to lay up cable based volume, length per piece, size, and customer requirements.
Lay Tables. Lay tables are utilized for lengths of cable up to 120 feet and 2 inch bundle diameter. Lay tables are used for lower volume runs, and can be set up to any length to minimize scrap material. Nortech utilizes servo motor controls to regulate lay length (twists per inch) and tape overlap.
Planetary Cabling. Planetary type cabling equipment is used for long continuous lengths of cable up to 1.25 inch bundle diameter. It is most useful for high volume runs over a few hundred feet.
Hand Layup. Hand layup is used for very short lengths of cable of a few feet or for cables with junctions (breakouts). Hand layup is also used to incorporate prewired connectors or switches into a cable assembly. During hand layup, the wires are formed as a helix by hand to the desired lay length. Hand layup can be performed with multiple lay patterns.
Lay Patterns. All layup techniques are available in any desired helical lay pattern. Lay patterns include bunch stranding, true concentric stranding (contrahelical), equilay stranding, unidirectional concentric stranding, unilay stranding, and rope stranding. Nortech equipment and techniques eliminate backtwist in the conductors.
A&D Binding Tapes Capabilities
Separator, or binding tapes, are used in cable layup to hold the layers together and provide increased electrical isolation. Tape under the cable jacket allows for easy jacket stripping and prevents extruded insulation penetrating the braid or conductors. Tape is applied during the cable layup operation, by hand on breakout cables, or through specialized taping equipment over and between braids.
- Mylar (polyester) tape is commonly used as an industry standard because of low cost, excellent insulation properties, and mechanical strength. Typical Mylar tape is made in accordance with MIL-I-631, Type G, Form Tf, Class 1, .001 inch nominal thickness.
- Aluminized Mylar tape is a polyester aluminum laminate used both as a binder/separator and to increase EMI protection. Typically, the conductive side of the tape is in contact with a braided shield or drain wire. Aluminized Mylar can be applied both under and over a braided shield. Typical thickness is .0013 inch.
- Teflon (PTFE) tape is used where increased flexibility is required. Teflons low coefficient of friction allows wire layers to slide upon each other during flexing.
A&D Braiding Capabilities
Metal or textile braids are available to provide EMI and mechanical protection. Braids can slide over cables or be braided directly onto cables.
- Nortech has machine capability in 16, 24, 32, and 48 carrier configurations
- Custom bobbin winding is done in house to provide the optimum combinations of optical coverage, braid angle, flexibility and flex life. Strand size from 30 AWG to 38 AWG available
- Tin coated copper and silver coated copper braids in accordance with A-A-59596 (QQ-B-575)
- Nickel-copper alloy (Monel) and stainless steel braiding available as armor over cables or harnesses
- Textile braids such as Nomex, Halar, or polyester available braided as protective coverings on wire harnesses
- Kevlar braids available to provide pull strength and mechanical protection
- Continuous braiding is available to braid directly on the cable through junctions providing 360 degree coverage
- Composite metal clad fiber braid materials available
A&D Jacketing Capabilities
Nortech has capability to extrude or install most any kind of jacket [sheaths]. Jackets are the flexible outer covering of cables used to protect the cable from the environment and physical stresses.
- Blown on tubing. Blown on tubing is rubber or thermoplastic tubing that is installed over cable cores using air pressure. The tubing is expanded and then allowed to return snuggly over the cable. Tubing sizes up to 2 inch diameter with wall thickness between .031 and .125 inch are commonly used. Lengths can be up to 120 feet. Blown on tubing is available in many materials, some of the most common are listed below
- Polycholoroprene (Neoprene) per MIL-PRF-6855, Class 2, Type A, Grade 60, Fungal Resistant; Low temperature flexibility, general purpose
- Ethylene Propylene Diene Monomer (EPDM) per ASTM D 2000 M2DA607,Fungal Resistant. Low temperature flexibility, weatherability-UV resistance-water resistance
- Fluorocarbon Elastomer (Viton®) per ASTM D 2000 M3HK607A1-10B37C12EF31 or AMS 3216. High temperature resistant, Fuel-Hydrocarbon resistant
- Thermoplastic Polyurethane. Lubrizol Estane® 58300, 58202, 58370, many other suppliers. Abrasion and cut through resistant, rugged
Extruded. Nortech has the capability to extrude most common thermoplastics used in defense applications such as polyurethane or Santoprene™.
Shrink tubing. All types of shrinkable tubing can be applied. Nortech has equipment to efficiently slide on long lengths of tubing and shrink in place using in-line infrared heating equipment. All SAE-AMS-DTL-23053 are available as well has proprietary materials from Tyco Electronics, Sumitomo Electric Interconnect Products, and 3M.
Braids. Braids can be applied directly using a braiding machine or pre-purchased braids
A&D Junction Capabilities
Cables with junctions [Breakouts] are typically made with the longest leg length on a lay table, then the cable is untwisted as necessary before retwisting the individual branches by hand. The number of junctions in a cable is limitless, Nortech has produced cable designs with more than a dozen junctions.
A&D Optical Capabilities
Our processes allow us to incorporate optical fiber, copper wire, fluid hoses, strength members, or stiffeners in any combination to a bulk cable.
Utilizing standard military specification connectors with optical contacts, we can customize a rugged cable assembly with fiber optic and copper wire.
Fluid hoses can be added for air, nitrogen, coolant or any fluid and be combined with copper conductors.
Strength members such as Kevlar cords or steel aircraft cable can be added to the center of the cable layup and attached to connectors or external points.
Assembly Quality Control Capabilities
- Crimp pull testing is performed for each tool setup or die change and for each production lot.
- In-process quality checks for solder terminations and processes that cannot be inspected at final acceptance.
- Most assemblies utilize automated electrical test with mating connectors.
- 100% of assemblies are tested for continuity, insulation resistance, and dielectric breakdown (Hi-pot).
- Nortech provides compliance with SAE AS50881, IPC-A-610 Class 2 or 3, and IPC/ J-STD-001 Class 2 or 3.
- Nortech will work to your special quality requirements documents.