Extensive experience with a wide variety of cable designs for various applications and markets, including consumer, aviation, military, and cables designed to assist with production and testing activities. Experience with authoring cable assembly procedures, generating cable drawings (in SolidWorks), and outsourcing cable manufacture. All aspects of design including wire selection, shielding, crimping, and other cable assembly techniques. Also experience with selecting off-the-shelf cable solutions, which is frequently a better option than a custom design.
- Cable Drawings – tolerances, QA checks (defining critical and significant characteristics), Bill of Materials (BOMs), ISO 9001/AS9100 approval processes, and designing for third-party manufacture
- Complex Assemblies – mass-produced cable harnesses that include multiple connectors, data converters and storage devices embedded (shrink wrapped) into the cable, multiple layers of shielding and insulation, twisted pair differential (both RF and high-speed digital), and more
- Terminations – hand crimps, machine crimps, IDC crimp, flat flex, Zero Insertion Force (ZIF) connections,and more
- Minimalistic Design – compact cables using the latest advances in miniature connector technology, requiring deep understanding of wire gauge size, termination resistance, and voltage drop effects on circuit performance
- Ruggedized Cable Harnesses – water, shock, and sand proof cable designs
- Design for Conducted Emissions/Susceptibility – appropriate shielding techniques (typically designed in conjunction with proper PCB terminations), use of ferrite beads (both on-cable and on the PCB), and more
