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Cable Design & Manufacturing of a Snake Cable for the Audio Industry

Snake Cable
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Snake Cable
 

EIS was contacted by a customer with a request to design and manufacture a 24 pair snake cable that would be compatible in size and performance to a cable being supplied by a well-known Asian manufacturer for use in the audio/broadcast market. We reverse engineered the existing cable and designed a prototype using OFHC bare copper conductors, insulated with polypropylene and individually shielded and jacketed pairs. The inner and outer jackets of the cable incorporated extremely flexible PVC. Having a diameter of .795" the cable maintained insulation integrity and exhibited no behavioral differences during the soldering process. It also had better consistency with an inner jacket thickness, making the cable easier to strip, resulting in reduced labor time.

Able to withstand temperatures up to 60°C, it was determined by the customers that our cable was overall easier to process than the existing cable.

EIS offers a wide variety of cables for use in the audio/broadcast market, ranging from multi-pair snake cables to microphone, speaker, and instrumentation cables. If we don't have what you need, we have the knowledge and the skills to design and manufacture components to your specifications. The table below lists further details of this snake cable design and manufacture project.

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Cable Design & Manufacturing Project Highlights

Product Name 24 Pair Snake Cable
Product Description EIS designed a cable that is compatible in and size and performance to an existing cable for use in the audio/broadcast market.
Capabilities Applied/Processes Design
  • Incorporated customers design requirements along with reverse engineering of existing cable design.
Prototype Manufacturing
Wire Extrusion
Cable Core Twisting
Shielding and Jacket Extrusion
Equipment Used to Manufacture Part Extruder
Cabler
Wire Braider
Overall Part Dimensions 24 Pair 26 AWG Individually Shielded & Jacketed Cable
Diameter: Ø.795"
Length: 500ft multiple lengths
Tightest Tolerances +/- .005"
Materials Used OFHC Bare Copper Conductors
Fibrillated Polypropylene Fillers
Jacket: PVC
Insulation: Polypropylene
Colors Black
In process testing/inspection performed Prototype Review
Dimensional
Electrical
Features Withstands Temperatures Up to 60°C
Maintains Insulation Integrity and Exhibits no Behavioral Differences During the Soldering Process
Has Better Consistency w/ Inner Jacket Thickness
  • Makes Cable Easier to Strip
  • Results in Reduced Labor Time


Easier to Process Than Existing Cable Being Used
Industry for Use Audio/Broadcast
Turn Around Time Two weeks ARO
Delivery Location Northeastern, U.S.
Standards Met Customer Supplied Specifications
RoHS compliant
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