Military and defense technology is some of the most sophisticated in the world. It requires precision and accuracy to operate effectively, and it must remain durable through harsh environments as well as the wear and tear they place on your equipment.

Along with the machines, tools, and other equipment that your organization uses, the quality of your cables also plays an essential role. Transmitting data or electrical current between endpoints in these settings requires cable housing designed for environmental factors to protect against any threat that could cause disruption.

One of the most important components of a military-grade cable is its termination. Endpoints need to remain firmly fixed in place and bond tightly to your cables so that they can continue to deliver performance on a consistent basis.

Custom cable termination is the best way to achieve this goal. When you work with a cable assembly manufacturer, you can specify the specific materials, dimensions, and other factors that will create the ideal cable for your needs.

Today, we are going to review some of the essential benefits that custom cable termination can provide to your military or defense organization. First, let’s explain the term “cable termination” in more detail. 

What is Cable Termination? 

Cable termination does not involve canceling a subscription to AT&T or FIOS. Instead, it refers to the types of endpoints installed on a cable assembly. 

For example, when you are charging your phone, the part of the cable that is inserted into the device’s input jack is the terminal. The USB or Type-C terminal at the other end connects to the charger so that your phone can restore its battery life. 

Some terminals also require additional connectivity to remain secure. A coaxial cable’s terminal needs to be tightened so that it remains in place and is resistant to disconnection. 

Custom Terminal Sizes

One of the most significant benefits that you’ll notice with custom cable termination is the ability to specify the size of your terminals.

Off-the-shelf cable solutions come in pre-determined sizes, which might not always be the ideal fit for your application. This can cause a number of problems down the line, including:

  • Poor electrical connection due to a loose or poor fit
  • Damage to cable housing caused by over or under-tightening
  • Difficulty connecting or disconnecting cable ends

Custom cable termination ensures that your terminals will be the perfect size for your application, so you can avoid issues like the ones listed above. You can also size terminals to fit easily within tight spaces where standard sizes may be too large or bulky to ensure a secure connection.

Materials and Environmental Factors

In military and defense applications, it’s essential to consider the materials used in your cable assembly as well as any environmental factors that could affect its performance.

Some of the most common materials used in cable termination include:

  • Gold
  • Silver
  • Tin
  • Nickel alloys
  • Copper alloys

Each of these materials offers different benefits in terms of electrical conductivity, resistance to corrosion, and more.

Your cable assembly manufacturer will be able to advise you on the best material for your needs, taking into account any environmental factors that could affect its performance. For example, if you’re using cable in a marine environment, then it’s essential to choose materials that can resist corrosion from salt water.

The housing material of the cable also plays an instrumental role in its environmental performance. A custom cable can be crafted with nonstandard materials that can withstand common threats as well as not interfere with the terminals.

Nonstandard Terminal Configurations

Finally, one of the most significant benefits of custom cable termination is the ability to achieve nonstandard terminal configurations.

This could include anything from special shapes or sizes to specific arrangements that are not possible with standard cable solutions. This benefit is particularly useful in military and defense applications where a cable might need to connect two devices in an unusual way or achieve a unique function.

For example, a cable used in an aircraft with limited space may need a terminal that is positioned at a right angle. This would not be possible with a standard cable, but it can be easily achieved through custom cable termination. Instead of having to chain multiple cables together or force a standard cable endpoint into a tight space, you can instead use one natively designed for the environment you plan to use it in.

Custom cable assemblies can also be used to recreate cables that may no longer be in production. You can provide the specifications for your required terminals and they can be recreated with superior performance quality to restore and sustain the functionality of your equipment. 

Get Custom Cable Termination with Midcon

Since 1972, our team at Midcon Cables has provided 100% U.S.-made custom cable assembly solutions for military and defense organizations. We start with your specific requirements and then reverse-engineer a solution designed to deliver consistent performance through even the most extreme environments. 

To learn more about how we can provide a custom cable termination solution for the field, contact us today.