Custom Wire Rope Cable Assemblies

wire rope cable assemblies

Wire rope cable assemblies are crucial in various relevant industries today, providing efficient and secure solutions for lifting, pulling, and supporting heavy loads. Customizing these assemblies ensures optimal performance, safety, and cost-effectiveness, tailoring them precisely to the application’s requirements. This level of customization enhances flexibility and reliability compared to off-the-shelf options. Additionally, custom wire rope cable assemblies excel in challenging environmental conditions, as appropriate materials and coatings are selected to withstand extreme conditions like high temperatures and corrosive environments. This adaptability promotes innovation and problem-solving, enabling engineers to address unique challenges creatively. By harnessing the benefits of customization, custom wire rope cable assemblies remain indispensable components across diverse industries and applications.

Understanding Wire Rope Cable Assemblies

Anatomy of a Wire Rope Cable Assembly

A wire rope cable assembly consists of several key elements that work together to form a functional and robust unit. These elements include:

Wire Strands

These are the individual wires that form the core and outer layers of the cable. These strands are twisted together to provide strength and flexibility.


This is the central part of the wire rope that serves as the foundation for the outer layers. The core can be either a fiber core or an independent wire rope core (IWRC), each offering different characteristics.

Outer Wires or Strands

These are the multiple layers of wires that surround cables with cores, as well as a variety of smaller cables that contain no core at all. The number of strands and wires in each strand determines the cable’s configuration (e.g.7×7, 7×19, 1×19 6×19, 7×19, 6×37).

Outer Coatings

Wire rope aircraft cabler frequently covered with a polymer coating. Usually black or clear vinyl is used, but any custom color can be produced as long as one is willing to pay the extrusion costs. The coating helps protect the wire rope from abrasion to heavy use over pullies and other consistent wear and tear. Even more robust and exotic coatings are available including: Pebax, Nylon 11, vinyl with UV inhibitors to protect from sun damage and cold resistant polypropylene.


Wire ropes are often coated with lubricants to reduce friction between individual wires, improving flexibility and extending the cable’s lifespan.

Key Components and Their Functions

End Fittings

A large variety of components can be swaged/crimped to the ends of the wire rope cable assembly to facilitate connections to various equipment or structures. All manufacturing lines at Tyler Madison Inc. are tested to ensure that the end fittings hold to breaking strength before the production process begins. A swaged end fitting is basically a cold weld. Common end fittings include loops, thimbles, stamped eyes, snap hooks, ball shanks, sockets, clips and threaded studs.

Sleeves and Stops

Stops terminate the wire rope, prevent unraveling and create a holding point. Sleeves are crimped around the cable to create a loop, to which different parts can be affixed.


Thimbles are small, metal fittings inserted into the sleeve made loops mentioned above to protect and reinforce the loop. They serve to prevent wear and deformation caused by contact with connectors or hooks, ensuring the integrity and longevity of the wire rope assembly. Thimbles play a crucial role in maintaining the shape of the eye loop and enhancing the strength and safety of the wire rope. 

Materials Used in Wire Rope Cable Assemblies

Aircraft cable can be made of various materials such as carbon steel, synthetic fiber, copper-clad, and more. But here at Tyler Madison, we focus on galvanized steel and stainless steel for our custom wire rope cable assemblies.  

Galvanized Steel

Galvanized steel wire ropes are widely used in various industries due to their cost-effectiveness and reliable performance. The zinc coating provides significant benefits, it protects steel from exposure to moisture and other corrosive elements, enhancing the cable’s longevity for outdoor and humid conditions. With excellent tensile strength, they are reliable for general-purpose applications in construction, agriculture, and lifting operations. Regular maintenance, including inspections and lubrication, ensures optimal performance and extends the life of galvanized steel wire rope cables.

Stainless Steel

Stainless steel wire rope cables are renowned for exceptional corrosion resistance, making them ideal for challenging environments. Composed of high-chromium steel alloys, they form a passive oxide layer that shields against corrosion. These cables excel in marine, offshore, and chemical processing applications, as well as coastal regions exposed to saltwater. Despite their corrosion resistance, they offer impressive strength and durability, suitable for tough applications. Their hygienic properties and attractive appearance find use in food processing, pharmaceuticals, and architecture. Moreover, stainless steel wire ropes require reduced maintenance compared to galvanized steel, with lower risk of corrosion-related failure.

Advantages of Custom Wire Rope Cable Assemblies

As discussed, custom wire rope cable assemblies offer a multitude of advantages over standard off-the-shelf options. By tailoring the design and construction to specific applications, these customized solutions provide unparalleled benefits, making them the preferred choice in various industries. We discuss these advantages in greater detail below. 

Increased Functionality and Versatility

One of the primary advantages of custom wire rope cable assemblies is the ability to optimize their design for specific functions. Manufacturers can engineer wire ropes with varying configurations, diameters, and end fittings to suit the unique requirements of different applications. This level of customization allows for increased functionality and versatility, enabling the wire rope cable assembly to perform optimally in a wide range of tasks, from heavy lifting and load-bearing operations to intricate rigging and support systems.

Enhanced Durability and Strength

Custom wire rope cable assemblies are built with careful consideration of the application’s load capacity and environmental conditions. As a result, they exhibit enhanced durability and strength, ensuring reliable performance even in challenging and demanding scenarios. Manufacturers can select the appropriate materials, wire rope constructions, and coatings to resist wear, corrosion, and fatigue, extending the cable’s lifespan and reducing the risk of premature failure.

Improved Safety and Reliability

Safety is of paramount importance in any application involving wire rope cable assemblies. Customization enables engineers to precisely match the wire rope’s specifications to the intended load capacity and working conditions. This attention to detail enhances the assembly’s safety and reliability, minimizing the risk of accidents, equipment damage, or potential injuries to personnel. Custom wire rope cables undergo rigorous testing and quality control measures, ensuring compliance with industry standards and regulations.

Tailored Solutions for Unique Applications

Not all applications fit within the standard parameters of off-the-shelf wire rope cables. Customization provides tailored solutions for unique and specialized applications. Whether it involves adapting to challenging environments, handling non-standard loads, or meeting specific industry regulations, custom wire rope cable assemblies effectively offer the flexibility to address these distinct requirements. This level of customization empowers industries such as aerospace, marine, construction, and entertainment to find reliable and innovative solutions for their specific needs.

Factors to Consider in Custom Wire Rope Cable Assemblies

When designing and manufacturing custom wire rope cable assemblies, several critical factors must be carefully considered to ensure optimal performance and longevity. These factors encompass various aspects, ranging from the specific application requirements to safety considerations and budget constraints. Here are the key factors to take into account:

Work Load and Load Capacity

Determining the workload and load capacity is paramount in creating a reliable custom wire rope cable assembly. Engineers carefully calculate the expected forces and stresses the assembly will undergo during its operational life. This involves considering static and dynamic loads to select the appropriate wire rope diameter, construction, and strength. The ratios used are typically 5:1 for a working load, and 10:1 for a shock or safety load.

Abrasion and Wear Resistance

Wire rope cables may encounter abrasion and wear from contact with other surfaces or equipment, depending on the application. In such cases, selecting the right material and protective coatings is crucial to enhance the assembly’s resistance to abrasion, reducing the risk of premature wear and failure.

Cycle Life and Fatigue

Some applications involve repetitive loading and unloading cycles, causing fatigue in the wire rope. Factoring in the cycle life and fatigue resistance is essential to ensure the assembly’s longevity and reliability under cyclic stress conditions. Sharing your use conditions with us will help us design a task appropriate, longer lasting custom assembly.

Flexibility and Bend Radius

The flexibility of the wire rope cable assembly determines its maneuverability and ease of use in specific applications. Understanding the required bend radius and flexibility is vital to avoid kinking or damaging the wire rope during operation. 7×19 wire rope is often a good choice if flexibility is desired for the application.

Environmental Considerations

The operating environment plays a significant role in material selection and the overall design of the wire rope cable assembly. Factors such as temperature extremes, exposure to chemicals, moisture, and saltwater should be considered to ensure the assembly’s corrosion resistance and longevity.

Cost and Budget Constraints

Customization often involves balancing the desired features and performance with budget limitations. Identifying cost-effective materials and design options without compromising safety and performance is essential in creating an efficient and economical wire rope cable assembly.

Safety and Industry Standards

Safety should always be a top priority when designing wire rope cable assemblies. Ensuring that the assembly meets industry standards and regulations for the intended application is crucial to mitigate potential risks and ensure the safety of personnel and equipment.

Choosing the Right Manufacturer

Tyler Madison is a reputable and time tested manufacturer specializing in custom wire rope cable assemblies, including wire rope fittings, aircraft cables, Bowden cables, wire rope lanyards, and other steel cable assemblies. With a commitment to excellence, our skilled personnel utilizes the latest technology to deliver consistently reliable solutions at a cost-effective price. We take pride in collaborating with clients to turn their ideas into reality, providing expert assistance in wire rope design, airplane cables, safety cables, steel tension cables, wire rope thimbles, push-pull cables, and more. Our tailored approach ensures that each wire rope assembly meets specific application needs, from control cables to safety ropes. At Tyler Madison, customer satisfaction is paramount, and strict adherence to industry standards and meticulous quality control guarantee the highest standards of excellence for every product leaving our facility. Embrace the advantage of custom solutions that excel in performance and safety by partnering with us for your custom wire rope cable assemblies. 

Contact us today to experience our dedication to delivering top-notch wire rope cable assemblies that elevate the reliability and performance of your projects.

The Customization Process

At Tyler Madison, our goal is to provide you with a seamless experience in designing your custom wire rope cable assemblies. Before you reach out, gathering as much information as possible is essential to ensure we meet your specific requirements. Some important questions we’d like to know include: 

  1. What amount of force will be applied to your assembly?
  2. What end fittings might work for your application?
  3. Is the wire rope naked or coated in PVC, nylon or a special polymer? Do you need a specific color?
  4. What should the cable’s length be?
  5. How tight are the length tolerances for your assembly?
  6. What do you want the cable construction to be? If it is a control cable what is the bend radius?
  7. What quantity are you looking for?

To streamline the process for our customers, we’ve also developed a custom wire rope assemblies configuration page, making it easier to send RFQs.

Once we receive all the necessary information and answers, our team can initiate the design and prototyping process. This allows us to conduct real-world testing, ensuring that the assembly not only meets performance expectations but also exceeds your expectations. After successful prototyping and testing, the custom wire rope cable assembly moves into full-scale production. During this phase, we maintain stringent quality control measures to guarantee consistency and precision throughout. Each wire rope cable assembly then undergoes meticulous inspection to ensure compliance with your design specifications, industry standards, and safety requirements. At Tyler Madison, we take pride in delivering custom wire rope cable assemblies that are tailored to your unique needs, providing enhanced performance, safety, and reliability for a wide range of applications.

Key Takeaways

  1. Custom wire rope cable assemblies offer tailored solutions that excel in performance, durability, and safety for various industries.
  2. Tyler Madison is a reputable and quality manufacturer specializing in a wide range of custom wire rope cable assemblies, including wire rope fittings, aircraft cables, Bowden cables, wire rope lanyards, control cables and more.
  3. With a commitment to excellence, Tyler Madison utilizes the latest technology and skilled personnel to deliver consistently reliable products at cost-effective prices.
  4. Collaboration with clients is at the core of Tyler Madison’s approach, turning ideas into reality by providing expert assistance in wire rope design and engineering.
  5. Tyler Madison’s wire rope cable assemblies are tailored to meet specific application needs, ensuring optimal performance, from control cables to safety ropes.
  6. Strict adherence to industry standards and meticulous quality control guarantee the highest standards of excellence for every wire rope assembly leaving Tyler Madison’s facility.
  7. Embrace the advantage of custom solutions that excel in performance and safety by partnering with Tyler Madison for your custom wire rope cable assemblies.
  8. Tyler Madison’s dedication to customer satisfaction and reliable products makes them a trusted partner for elevating the reliability and performance of your projects. Contact us today to experience our commitment to excellence.

How to Choose the Right Cable for your Cable Assembly

push-pull controls

Cable assemblies are groups of cables put together to serve a particular purpose. Other names for cable assemblies are custom wire rope and wire rope lanyards. These cables are packaged together in the ideal length and direction to speed up and simplify installation. Depending on the use, they can come in various sizes, colors, and lengths, along with different cable constructions.

Guidelines for Choosing the Right Cable for Cable Assembly

Following are some important considerations to keep in mind while selecting the right cable:

For Cable Assembly Design:

  • Keep in mind how much workload the cable will bear, forces of abrasion upon it, and whether it needs to be flexible for its use.
  • Do you want to lean towards cost savings or high quality?
  • Ensure that the safety ratio is carefully managed. A 5 to 1 ratio breaking strength ratio is recommended for most applications
  • The diameter of the small wires found in the bundle is inversely proportional to its flexibility, meaning if more wires are chosen for cable assembly, they will be smaller. For example, ⅛” 7X19 cables will be more flexible and have more wires than  ⅛” 7X7, but the latter will be more abrasion resistant.
  • If tensile strength is the primary concern, then galvanized steel is slightly better than stainless steel; in the case of corrosion resistance, stainless steel outperforms galvanized steel
  • To maintain flexibility and a bigger diameter, 7×19 is necessary because coatings will add some stiffness. Pebax and Nylon 11 coatings, which are incredibly strong and flexible, are ideal for pulley systems, such as those found in exercise machines.
  • The cost and quality of the cable go up with tighter length tolerances, as this increases the amount of labor dramatically.

For Control/Push-Pull Assembly Design:

  • The workload  should come under primary consideration and attention for a control cable assembly or push-pull cable.
  • The assembly should be routed carefully, keeping in mind the bend radii and the anchoring of the assembly.
  • The dimensional specifications, such as the length and diameter of the inner wire and conduit, along with how much the wire will travel, are equally important considerations.
  • Knowing the precise measurements of the control assembly is important when making design decisions. After obtaining the prototype of the required push-pull control assembly, it may be required to make a few minor adjustments.
  • To minimize the impacts of friction within the push-pull assembly, the conduit bend radius should be maximized while building a working model of the push-pull control assembly. With a lesser load, lighter casings will be more flexible and slack. There won’t be much flexibility with higher loads and heavier casings.

Applications of the Cable Assemblies

Tyler Madison cable assemblies find their use in a long list of applications. Following are some of the prominent applications of cables assemblies:

  • Accelerating
  • Actuating
  • Choke
  • Connecting
  • Driving
  • Hanging
  • Lifting
  • Supporting
  • Suspending
  • Regulating
  • Restraining
  • Winding