Multi-conductor cable dimensions are influenced by conductor count, conductor size, stranding type, insulation thickness, shielding architecture, and jacket selection. Final dimensions are determined during engineering review based on application requirements.
Typical Outside Diameter Ranges
Multi-conductor cables are commonly produced within the following nominal OD ranges:
- Small-format cables: approximately 0.060″ – 0.150″
- Medium-format cables: approximately 0.150″ – 0.350″
- Large-format cables: approximately 0.350″ – 0.600″
Actual OD varies based on construction and materials.
Factors Affecting Cable Diameter
Several design elements directly impact finished cable size:
- Number of conductors
- AWG size and strand construction
- Insulation wall thickness
- Shielding type (individual, group, or overall)
- Jacket material and wall thickness
Design tradeoffs often balance diameter, flexibility, and durability.
Flat and Specialty Configurations
Dimensional profiles vary for non-round constructions:
- Flat or bonded ribbon cables
- Figure-eight and double-D profiles
- Ripcord and multi-member designs
Widths and thicknesses are application-specific and defined during design.
Mechanical Considerations
Dimensional selection should account for:
- Bend radius and flex frequency
- Routing constraints and strain relief
- Weight and handling requirements
- Long-term fatigue performance
Smaller diameters generally improve flexibility but may limit durability or shielding options.
Engineering Support
Dimensional targets are best established early in the design process. Gavitt works with customers to evaluate space constraints and performance requirements and to recommend constructions that balance size, flexibility, and service life.