Cable assemblies used in demanding environments need to do far more than simply maintain an electrical connection. Exposure to water, dust, vibration, extreme temperatures, chemicals and mechanical stress can all affect their performance and shorten the lifespan of components.
For applications where reliability is critical, careful material selection, effective sealing and appropriate environmental testing should be considered from the earliest stages of cable assembly design. At Novara Technologies, we work with customers to develop bespoke cable and interconnect solutions designed around the requirements of their intended applications.
What makes an environment ‘harsh’ for a cable assembly?
A harsh environment is any setting where a standard cable or connector could be exposed to conditions that compromise its performance.
Outdoor equipment, industrial machinery, automotive systems, marine electronics and certain medical devices can all face environmental challenges. Moisture and contamination can lead to corrosion or electrical failure, while repeated vibration, abrasion and temperature changes can weaken cables and termination points over time.
Understanding these conditions allows engineers to select suitable materials and construction techniques before production begins.
When are waterproof cable assemblies required?
Waterproof cable assemblies are particularly important when equipment is exposed to rain, splashes, washdowns or immersion.
Achieving a reliable waterproof design involves more than selecting a water-resistant cable jacket. Potential ingress points around connectors, terminations and cable entry points must also be considered.
Techniques such as overmoulding can provide additional environmental protection while also improving strain relief and durability. Suitable sealing methods, including gaskets, O-rings and specialist sealing materials, may also be incorporated depending on the design.
Understanding IP67 and IP68 cables
Ingress Protection ratings provide a useful way to specify the level of protection required against solids and liquids.
IP67 IP68 cables are commonly considered for applications where a high degree of resistance to dust and water ingress is required. However, an IP rating should always be considered alongside the specific application and testing requirements rather than treated as a general guarantee of performance in every environment.
Factors such as immersion conditions, operating temperature, pressure, connector design and repeated mating cycles can all influence the suitability of an assembly.
Testing the finished cable assembly against the required environmental specification is therefore an important part of product development.
Why are sealed cable connectors important?
A cable system is only as resistant to environmental ingress as its weakest point. For this reason, sealed cable connectors play an important role in harsh-environment applications.
Connector selection needs to consider the sealing system as well as electrical requirements. Engineers may need to assess contact configuration, mating method, strain relief, cable diameter and the materials used within the connector assembly.
Where an off-the-shelf connector cannot meet the requirements, a bespoke solution may provide greater control over sealing, ergonomics and overall performance.
Material selection and mechanical protection
Different environments demand different cable materials. Jackets may need to withstand abrasion, UV exposure, oils, chemicals or temperature extremes, while shielding may be necessary where electromagnetic interference is a concern.
Mechanical protection is equally important. Overmoulding, cable sheathing, braiding and appropriate strain relief can help protect vulnerable termination points from movement and repeated stress.
Taking these factors into account during the design stage can improve long-term reliability and reduce the likelihood of premature component failure.
Bespoke cable assemblies from Novara Technologies
At Novara Technologies, we specialise in developing custom cable assemblies and interconnect solutions for demanding applications. By considering environmental conditions, materials, sealing, connector requirements and manufacturability from the outset, we can help customers develop solutions suited to real-world operating conditions.
Whether a project requires waterproof cable assemblies, robust sealed cable connectors or cable systems designed to meet specific ingress protection requirements, early collaboration can help create a more reliable and manufacturable final product.
Speak to Novara Technologies about your next bespoke cable assembly project.