Custom Wire Rope Assemblies
Ohio-Assembled Excellence Since 1956

Roy I Kaufman manufactures custom wire rope assemblies up to 1/8" diameter. We specialize in small-diameter cables ranging from 3/64" to 1/8", available in both 7x7 and 7x19 constructions. Our wire rope assemblies can be manufactured in stainless steel (304/316), galvanized aircraft cable, or PVC coated finishes. Whether you need a single prototype or production volumes exceeding 1,000,000 pieces, we can accommodate assemblies from 6 inches to 100+ feet in length. Request a quote for your specific cable diameter and length requirements.

Roy I Kaufman primarily manufactures custom wire rope assemblies with end fittings, but we also offer cut-to-length cables and bulk quantities of certain sizes and constructions. Our focus is on complete cable assemblies tailored to your specifications, but we understand that some applications require bulk wire rope or cables without terminations. We maintain inventory of commonly requested cable constructions (7x7 and 7x19) in various diameters. Contact us to discuss bulk cable availability, or use our 3D wire rope configurator to design a complete assembly with end fittings.

A cable assembly (also called a wire rope assembly) is a complete cable solution consisting of three main components: the wire rope or cable itself, end fittings or terminals on one or both ends, and optional accessories like protective sleeves or stops. Unlike bulk cable sold by the foot, a cable assembly is a ready-to-install component manufactured to your exact specifications.

Custom wire rope assemblies typically include:

• Wire rope core: 7x7 or 7x19 construction in your chosen diameter and material
• End fittings: Swaged eyes, eyelets, end stops, hooks, or custom machined fittings
• Length specification: Cut precisely to your required dimensions
• Finish options: Bare galvanized, stainless steel, or PVC coated

Common applications include fitness equipment cables, automotive brake cables, construction safety lanyards, marine rigging, and industrial control systems. At Roy I Kaufman, every wire rope assembly is manufactured in Ohio. Design your own assembly using our interactive 3D configurator, or request a custom quote with your specifications.

Yes, Roy I Kaufman's engineering team can leverage our 65+ years of wire rope experience to help you design the optimal cable assembly for your specific application. Our engineers will work with you to determine the best wire rope construction (7x7 vs 7x19), appropriate cable diameter, suitable end fitting types, and any specialized requirements like corrosion resistance or high-flex applications.

We're happy to provide prototypes and samples for qualified applications at no charge for suitable projects. Our design assistance services include:

• Cable construction selection and load calculations
• End fitting compatibility recommendations
• Material selection (galvanized, stainless steel, coated)
• CAD drawings and technical specifications
• Quality documentation

Start designing your custom wire rope assembly instantly with our 3D configurator tool, or request engineering assistance for complex applications requiring expert guidance.

The difference between 7x7 and 7x19 wire rope construction affects flexibility and strength characteristics of your cable assembly:

7x7 Construction

Our 7x7 wire rope consists of 7 strands with 7 wires each (49 total wires):

• Moderate flexibility
• Higher strength-to-diameter ratio
• Best for static applications or limited flexing
• Common in safety lanyards, guy wires, and control cables

7x19 Construction

Our 7x19 wire rope consists of 7 strands with 19 wires each (133 total wires):

• Superior flexibility and fatigue resistance
• Ideal for applications requiring frequent bending or cycling
• Common in fitness equipment, automotive applications, and aircraft controls

Both constructions are available in all our custom wire rope assemblies. Our engineering team can help you select the optimal construction for your application. Use our 3D configurator to visualize both options, or request technical guidance.

Roy I Kaufman offers a comprehensive range of end fittings for custom wire rope assemblies:

• Swaged Eyes: Open or closed loops in various sizes
• Eyelets: Reinforced attachment points for securing with screws or bolts, ideal for lanyards and retention
• End Stops: Spherical ball ends or cylindrical end stops for various applications
• Hook Terminals: Snap hooks, S-hooks, and custom designs
• Custom Machined Fittings: CNC machined to your drawings

Fittings are attached using professional swaging or mechanical crimping methods depending on fitting type, cable diameter, and application requirements. Both attachment methods provide maximum holding strength and reliability. We can combine different fitting types on each end of your wire rope assembly. Visualize fitting options with our interactive 3D configurator, or request a quote with your specific terminal requirements.