Case Studies
Not everyone gets as excited as we do about actuating a throttle on a gas motor or securing a stylus pen for a Nintendo 3ds. So we are using this space to highlight some of our more exciting and creative cable and wire rope projects.
Commercial Fitness Equipment Cable Assemblies
How Tyler Madison Engineered a 93-SKU Reshoring Program for a High-Cycle OEM
When a commercial fitness equipment manufacturer moved cable production offshore to cut piece costs, they got what they paid for — inconsistent dimensions and higher failure rates on cables that take constant pulley wear in high-traffic gyms. In 2022, they came back to Tyler Madison.
We rebuilt the line around a 1/8″ 7×19 galvanized wire rope with a Pebax coating instead of Nylon 11 — a material switch that holds up far better under repeated bending around pulleys — paired with a ball-shank termination that lets field technicians swap cables with just a socket wrench. Today Tyler Madison manufactures and maintains all 93 active part numbers in the program, and 2024 was the account’s second-highest sales year in a 20-plus-year relationship.
Avalanche Airbag System
How Tyler Madison Engineered a Custom Rip Cord
When Wary set out to build an avalanche airbag system, they needed a rip cord that could perform when it mattered most — in sub-freezing conditions, worn on a skier’s shoulder through hard use. Standard materials couldn’t hold up.
Tyler Madison engineered a custom rip cord using a 3/64″ lined, longitudinally braided conduit with a black polypropylene cover. The longitudinal braiding keeps the assembly from separating under the stress of being worn and pulled, and the polypropylene coating is engineered to resist cracking 30–40°F below freezing.
“Working with Cal has been awesome — he was willing to sit down and really listen to what I wanted,” says John Bowker, Wary’s owner. “Proximity, being able to work one-on-one with Calvin, was a huge factor in the design process.”
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