The idea behind "Cable in Cable" is that you can
combine several wires into one outer jacket to share
power and communications. It makes installation
easier. Our Cable-in-Cable products are fully
customized - tell us your requirements, and we'll
group the right wires and materials into a single
jacket.
Figure: An overmolded cable assembly with built-in
power and signal connections. A cable-in-cable is a
group of conductors that are all inside one outer
sheath. It is a single design that includes both
power and data cables. With its multi-conductor
layout, this design makes wiring easier and cuts
down on clutter. In a cable-in-cable setup, power
and signal lines (like two Ethernet pairs or USB)
share a jacket. For example, a single hybrid
connection could give a device both network data and
12V power. Putting these groups together makes
installations faster and cleaner. If we need to, we
can even add parts inline. We make each cable to
your exact specifications, making sure that the
number and function of the cores are just right for
you.
In cable-in-cable systems, the wires for the data group
and the power group are put together as one assembly.
The power group carries DC or AC power, while the data
group carries information like Ethernet, USB, or sensor
signals. When the cables are put together in one jacket,
they serve two purposes. For example, a custom Ethernet
cable might have extra DC power connections so that a
single line can send power and data to a camera. These
hybrid cables cut down on mess and installation time. We
make sure that the power and data lines in a single
cable are up to code by carefully lining up each group
and picking the right materials.
Network cable with power group
Power conductors can also be found in network
cables. We make hybrid network connections by
using both Ethernet pairs and extra power wires.
For example, we can make a network connection
that is safe to use in walls by combining four
Cat6 data pairs with a low-voltage power line.
This lets you use just one jacketed wire to
power a camera or PoE device. These cables make
setups easier by getting rid of the need for
separate power lines. Not only do they have
insulation to meet building codes, but they may
also have shielding to keep data signals clean
even when they are close to power sources.
UTP cable with power group
Even regular UTP cables can carry power
conductors. We add extra wires to the twisted
pairs in a UTP cable. In short, it's like PoE,
but one cable carries both the power and the
signal. This hybrid UTP connection can have the
usual four data pairs and two power lines. This
is the best way to go if you don't want to use a
lot of cables in your installation. The cable
keeps the UTP protocol's signal quality while
also powering the device. Everything is in one
sheath for easy deployment.
USB cable with power group
We can use the data and 5V electricity that USB
connections already send better. As an example,
we could make a USB cable with three connectors
that can power and send data to three different
devices at the same time. If you need more
power, we can also give you extra power leads.
These USB hybrid cables have a single jacket
that hides many ends, such as micro, USB-C, and
Lightning connectors. They make it easier to
charge and get data from consumer devices. These
wires are strong and flexible, so they can
handle regular use.
Large power and small signal integrated
Some cables carry heavy power lines as well as
sensitive communications. One possible cable
setup is a small control wire with a
high-current AC feed. In our design for an AC in
a power cable, we put together a mains line and
low-voltage control lines. An analog in cable
might also have power and analog sensor wires in
it. Hybrid wires are often used in machines and
systems that need power and control. The cable
has insulation to protect both the signal wires
and the heavy power conductors. This integration
means that you only need to run one long cable
instead of two separate ones, one for power and
one for signal.
Cable groups organization
We put our cables into groups based on how they work, so
we can get the most use out of them. Our designs use
cables in insulation to protect the actual wires. Here
are some examples of how jackets and insulation can work
together:
PVC + Teflon groups
A PVC jacket and Teflon (PTFE) insulation work well
together to keep heat out and make the jacket
flexible. Both the PVC outer layer and the PTFE
inner layer can handle very high temperatures. The
PVC layer is also hard and resistant to chemicals.
These cables work great when only a small part of
the wire is exposed to high temperatures or
chemicals.
TPE + PVC group
We use cores made of PVC that are insulated and
covered with a flexible TPE jacket, or the other way
around. PVC is cheap and doesn't absorb moisture,
while TPE is flexible and soft even when it's cold.
For example, a PVC cable wrapped in a TPE jacket is
very flexible and won't break if you bend it over
and over. This group is perfect for cables that are
always moving.
TPU + TPE group
TPU and TPE are two types of elastomers that are
known for their great performance. The TPU jacket
and TPE inner layers work together to make the cable
very flexible and resistant to wear. These cables
are great for robotics or motion control because
they can bend a lot without breaking. They don't get
as greasy, scratched, or damaged by UV rays as
regular PVC.
PVC extruded + PVC tube
This design uses two layers of PVC. An extruded PVC
core surrounds the embedded conductors in a separate
PVC tube. Picture a cable with two layers of PVC. A
strong, round cable is made, and it's easy to peel.
The extra tube makes the cable stronger for everyday
use and protects it from impacts.
Cable groups custom service
We offer a fully custom cable group design to meet your
specific needs. Our engineers will set up the wires and
functions according to your instructions, sorting them
by data and power. We choose materials and insulation
based on what each group needs. We'll take care of it if
you just tell us what you need. We always keep your
needs in mind and make sure that the cable system fits
them from the start. We make each custom cable to order,
taking into account your exact wire grouping and
performance needs.
Provide request of your needs
All you have to do is tell us what you need, and
we'll take care of it. Please tell us how many
wires, what voltages, what kinds of signals, and
what kinds of connectors you want. We can help
with things like insulation types, jacketing,
and wire gauge. Our team will go over everything
with you, no matter how specific your request
is. Based on your feedback, we chose the best
number of cores and wire arrangements. This
makes sure that the finished cable is exactly
what you want. You can also ask for special
color coding or branding to be added.
We can turn your wire specifications into exact
technical drawings. Our staff makes wiring
diagrams or cable schematics and sends them to
you to look over. The drawings show the colors,
materials, labels, and layout of the core. We
check the size, shielding, and jacket layers on
the sketch. Before production starts, you can
look over and approve the design. This way, you
can be sure that the cable assembly will work
perfectly for what you need it for. We keep the
drawing on file so that all future orders will
use the same design.
We also specialize in working in very tough and
extreme conditions. We make Cable-in-Cable
systems that can handle very high or low
temperatures, chemicals, water, and pressure.
For example, cables that are meant to be used in
airplanes or underwater must have certain
coatings and jackets. We use fireproof or
waterproof materials to insulate when we need
to. Our cables for use in extreme environments
come with protected connections, braided
shields, and jackets that resist oil. We
carefully choose the materials for your cable so
that it works reliably in places where other
cables don't, like the military, oil and gas, or
maritime sectors.
With a cable-in-cable harness, one small cable
can carry both power and control. Their use is
good for robots, industrial machines, and other
kinds of mobile equipment. Strong outside
coverings keep grease, wear, bending, and heavy
use from getting to the inside.
Telecommunications & Security
These cables are smartly designed so that they
can send both data and electricity at the same
time. All of the wires are safely bundled
together and protected by a strong outer case.
This not only speeds up the installation
process, but it also saves space and keeps the
wiring neat and tidy.
Medical & Life Sciences
Medical equipment needs a signal that is safe,
steady, and clear. These cords not only keep the
power on all the time, but they also send ECG
and EEG data. They are made of soft, safe
materials that last a long time, can be used in
many ways, and are easy to clean.
Aerospace & Defense
Aircraft and military systems need wires that
are light but very strong. These wires can
handle very high and low temperatures, changes
in pressure, and strong vibrations. They follow
strict safety and quality rules to make sure
that the results are always the same.
Automotive & Electric Vehicles
Wires are needed for cars that run on
electricity and data systems. This is a smart
way to connect motors, batteries, sensors, and
control units in small spaces. Insulation helps
keep things from vibrating, making noise, and
getting too hot.
Consumer Electronics & PCs
These cords have everything you need for power,
signals, and USB. They help keep cables from
getting tangled up in small electronics like PCs
and other devices. This has a lot of benefits,
including better airflow, cleaner goods, and
better overall performance.
Mechanical Strength Factors
Every cable needs to be strong enough to hold up.
The tensile strength of a cable tells you how much
stress it can take before it breaks. High tensile
strength is the ability to withstand tension without
breaking. Experts in the field all agree that this
is an important quality in cables. Compression
strength shows how well a cable can resist being
crushed or pinched when it is put under a lot of
pressure. The draw force rating tells you the safest
way to pull the wire through pipes and other holes.
We use aramid-strength fibers, extra jacketing, and
reinforced cores in our cable designs to get around
these problems. In fact, a cable that can handle a
lot of tension, compression, and pulling will stay
safe and work well during installation and use.
We can change the length of each wire to fit your
needs. There is less waste and cleaner installs when
there is no extra slack. We carefully measure and
cut the wires so that they fit snugly with your
machines.
Shielding
You can choose between foil, braid, and spiral
shielding, so you can find the one that works best
for your signal. The goal of shielding is to cut
down on electromagnetic interference. When there is
a lot of electromagnetic interference (EMI), we can
even use a mix of braid and foil.
Color
Pick jacket colors that make them stand out more.
Color coding is helpful when there are a lot of
cords. You can choose from our basic colors or have
them made to match your logo or system.
Printing
You can print your text or logo on the cable jacket.
You can find markings like part numbers, business
names, or instructions for use. ATI Electrical says
that all cables, no matter how long, come with
custom jacket printing. This makes it easier to find
each cable on site.
Fast Sampling & Production Lead Time
Fast Sampling
It usually takes us days, not weeks, to get
prototype samples back to you. If everything
goes as planned, we should be able to finish the
samples in about three days. This way, you can
quickly test the cable before you make a lot of
them.
Production Lead Time
Things like how easy it is to connect and how
complicated the cables are affect how long it
takes to make a lot of things. We improve our
process to meet quality standards with the least
amount of time needed. Once a design is
approved, full production runs usually ship in
weeks, not months.
We ordered a custom Cable-in-Cable assembly and were very impressed. It matched our specs exactly and works perfectly. High quality and fast service.
John Smith
The cable worked great and simplified our setup. Build quality is solid. Everything arrived as promised.
Jane Doe
Excellent service from QL-Custom. They delivered durable, well-made cable harnesses on time. We'll definitely use them again.
Mike Johnson
Great experience overall. The custom cable integrated our power and data lines beautifully. The on-time delivery was much appreciated.
Alice Williams
Perfect custom cable solution. The QL-Custom team helped us finalize the design, and the final product exceeded expectations. I highly recommend it.
Linda Davis
Cable-in-Cable solution is exactly what we needed. Robust and exactly to spec. The sample was ready in days, which was impressive.
James Wilson
Purchase Pro-Grade Cable in Cable Solutions
QL-Custom Technology Ltd. is the go-to company for
custom cables. We are experts in making custom
cables, and our ISO9001:2015 certification shows
that. We check every product carefully and promise
that all of our work will be done on time 96% of the
time. Our engineers are experts in everything from
basic harnesses to complex multi-cable systems. We
use the latest testing and technology to make sure
that everything works in every situation. When you
work with us, you can expect quick answers, detailed
designs, and cables that are made just for you and
meet all of your needs. Because of this, QL-Custom
is the best place to buy Cable-in-Cable solutions.
