Custom cable assemblies
Cables, assemblies, and harnesses
Send the spec. Polar Wire produces the engineering and production drawings, then builds the cable in Illinois. Arctic Ultraflex Blue, Arctic Superflex Blue, or the wire you specify. Prototyping from stock typically ships in 5 to 10 days.
Approvals and origin
1 to 3 conductor, 18 AWG to 1000 MCM
Terminations to 1000 MCM. IPC/WHMA-A-620 Class 3. UL and CSA listed or recognized components. Full production typically reaches shipment in 15 to 30 days. Orders under 50 assemblies ship within 10 days on average.
One cable, or a large production run. Custom cables have no minimum.
Crimp technology and validation testing
From crimp integrity to real-world performance testing.
Crimping standards
Large-gauge crimping with pull testing, micrograph analysis, and full validation.
Performance testing
Thermal, vibration, and load-cycle testing.
Custom tooling
Dies, terminals, and proprietary crimp profiles.
Two ways to buy
Create your own cable online
Design to your specifications, terminations, and accessories. Pay online with a 3-5 day production turnaround.
Cable configuratorTalk to Our Team
Describe your specifications, quantity, and delivery timeline. We will see what we can do to meet your goals.
Request a quoteCapabilities, lead times, quality
Capabilities
What Polar Wire terminates, and the lug families in the catalog.
What we can build
Lead times
Prototyping from stock typically 5 to 10 days. Full production typically 15 to 30 days.
The averages
Quality
UL/CSA listed components. Limited Lifetime Warranty on sealed custom cables.
The credentials
Prebuilt cables
Custom battery cables with affixed boots and labels to your specifications.
Shop prebuilt
Assemblies from the shop
Custom cable order form
Custom cables have no minimum.
Frequently asked questions
Send the spec. Polar Wire produces the engineering and production drawings. Prototyping from stock typically 5 to 10 days. One cable, or a large production run.
What do you need in order to quote a custom cable?
The application, the volume, and when you need it. A drawing helps if you have one. If you do not, Polar Wire produces the engineering and production drawings.
Can you build a cable to my drawing?
Yes. Send the drawing if you have one. Assemblies use UL and CSA listed or recognized components.
Can I order a custom cable on the online store?
The cable configurator at store.polarwire.com/custom-cables builds a one-off assembly to your gauge, length and terminations and takes payment. Drawings, non-standard terminations, private label and volume go on the quote form. Custom colors or a print legend on the wire are private label, from 10,000 ft.
Is there a minimum order on custom cable assemblies?
No. One cable, or a large production run. Custom cables have no minimum.
Request a custom assembly quote
Send the spec, or a drawing if you have one. Custom cables have no minimum.