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 custom cable assembly manufacturing, is the budget pledged to create it. At Carl Stahl Sava Industries we provide guidance in cable assembly design 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 50 years of engineering and production expertise to help you understand the key pricing factors that influence your budget.

Take a look at the cable costs, and considerations for designing and manufacturing your cable or wire harness assembly below or request a quote from our world-class, in-house engineering team.

What Goes Into Cost?

Cable Construction

Prevent corrosion, rust and chemical reactivity, promising your cable assemblies meet the lifespan your applications demand. Sava proudly offers passivation services for all of our cable, fittings and cable assemblies.--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.


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

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 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.


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



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!