Cost Considerations

WE UNDERSTAND HOW CUSTOM CABLE ASSEMBLY DESIGN IMPACTS YOUR BUDGET

Explore the cost considerations for your custom cable assemblies

A vital consideration that goes into determining how your product is built, is the budget pledged to creating it. At Carl Stahl Sava Industries we provide design guidance and assistance to organizations just like yours that require custom cable assemblies with sophisticated needs.

As a custom cable manufacturer, Sava knows firsthand how application design influences the cost of your products. From cable construction, to length tolerances, to the speed and reliability of production runs, count on Sava's almost 50 years of engineering and production expertise to help you understand the key pricing factors that influence your budget.

Take a look at the cost considerations below or request a quote from our world-class, in-house engineering team.

What goes into cost?

Cable Construction

Cable Construction

Fewer wires in a cable results in lower cost, but also less flexibility. Hence, a 1x19 (19 wires) will be less expensive than a 7x7 (49 wires) and a 7x7 will be less expensive, but less flexible than a 7x19 (133 wires) in the same diameter. Striking the right balance between cost and technical requirements is a delicate exercise that Sava can guide you through.

Material

Material

Stainless steel cable, using standard 302/304 stainless, will cost approximately 1.5 to 3 times more than galvanized steel cable, depending on the size and construction. Galvanized steel cable, with a plastic coating, will generally cost less than an equivalent stainless steel cable. Vinyl coating is less expensive than nylon, and FEP is the most expensive. Contact Sava’s sales team to discuss these and other types of cable and coating materials.

Strength Recommendations

Strength Recommendations

Specifying less than full strength on your cable assembly prints will usually result in lower pricing, accomplished by crimping the fitting over the cable coating. This can result in a loss of strength of approximately 35%. However, to obtain full breaking strength, the cable coating would then be stripped and the fittings swaged directly onto the cable. Also note that cables with 1X19 construction have less holding strength. Contact Sava’s sales team to discuss your cable assembly strength requirements.

Length Tolerances

Length Tolerances

Length tolerances are an important cost consideration as well. Close tolerances require more expensive cutting processes and increased inspection criteria. The cable sizes and fittings in use often determine attainable tolerances. Cable assemblies specifying precision tolerances must state under what load the length is to be measured. Do not over specify. Confirm with Sava's engineering team your desired tolerances prior to production. Standard tolerances will be used unless otherwise agreed upon.

Fittings

Fittings

The following is a ranking of the relative cost of fittings starting from the least expensive. The ranking is predicated on the cost of the fitting, and its cost of attachment to the cable, based on the assembly being manufactured by Sava: eye, ball-end plug, threaded plug, ball, ball & shank, loop, MS terminals.

Recommended Length Tolerances

LENGTH
(FT.)
TOLERANCE ± (IN INCHES)
PRECISIONTIGHTCLOSESTANDARD
0.1 - 2.0 1/64 1/32 1/16 1/8
2.1 - 5.0 1/32 1/16 1/8 1/4
5.1 - 10.0 1/16 1/8 1/4 1/2
10.1 - 20.0 1/8 1/4 1/2 1
20.1 - 40.0 1/4 1/2 1 2
40.1 - 60.0 1/2 1 2 4
60.1 - 80.0 1 2 4 8
80.1 - 100.0 2 4 8 16
100.1 AND ABOVE .5% of length .8% of length 1.5% of length

Talk to our world-class engineering team and discuss your project's technical requirements and let Sava help develop a cost-effective plan to proceed.

Let's discuss your next project or get a quote today!

CONTACT A CABLE EXPERT

Carl Stahl Sava Industries maintains a family of services and products certain to help you realize your cable product's complete potential.

At Sava we manufacture custom, small and miniature cable assemblies, and do so meeting the demands of clients operating in intensely competitive markets. Sava's customers comprise small, mid-sized and large national and multinational corporations. Sava knows that whether you require over-the-counter products or a fully customized cable assembly solution, we are serving customers that cannot afford quality issues or problems in production. Sava is proudly ISO 9001:2015, FDA, ITAR, RoHS and REACH certified and possesses a team of 100 of the world's most seasoned cable manufacturing experts.

To make it easy to explore our products, Sava provides you with a downloadable catalog and ordering guide.

Click the image of our catalog to download an electronic verion or painlessly  request a quote now.

Design Guide for Cable Solution