Fiber and Copper Hybrid Cable Case Study

At AngNet we support your project from design to production and delivery. You share the requirements and we take care of the rest.

Here is a real case study showing how a custom solution came to life.

Project Background：The customer is a large outdoor production team. Their projects require a large number of long cables, which makes on site cabling complex and difficult to manage. They wanted a customized hybrid cable that combines Ethernet and fiber to keep the setup cleaner and easier to manage.

Project Challenge: Network and fiber are very different cables. Bringing them together requires alignment across multiple suppliers and production teams, which puts strong demands on a company's coordination and problem solving ability.

Fiber and Network Hybrid Cable

Process of Delivery

Step 1: Understanding Customer's Needs

The customer requested a solution that combines Network and fiber cables, is suitable for outdoor use and rain-resistant, and is compatible with Sony cameras. Our engineers proposed an initial design using a figure-8 structure to combine fiber and copper with an armored build for durability. For the copper part, we used 23AWG 99.9% pure copper solid CT6A to meet the 802.3bt standardto ensure compatibility with Sony cameras.

Hybrid Cable Structure

Step 2: Sample Production

After the customer approved the specifications, our production team started opening the mold. During production, we encountered a few challenges. For example, the initial design of the fiber-copper connection part was 1.0mm, which risked sticking. To prevent this, we increased it to 2.0mm. The mold went through several improvements, and once it was ready, we produced and delivered the samples.

Samples

Step 3: Sample Feedback

The customer received and tested the samples. The cable's performance was perfect, but there were some issues with the RJ45 connectors. To ensure optimal performance, the Network cable used 1×0.57mm BC conductors, which increased the cable diameter to 6.8mm. As a result, the RJ45 boots could not fully cover the connectors, making them prone to cracking.

RJ45 Boot Issue

Step 4: Solving the Issue

After receiving the customer feedback, our engineers immediately began working on a solution. Since the network cable was too thick to be covered by normal RJ45 boots, we discussed and decided to customize a special RJ45 connector for the cable. We developed a 3D model and drawings, then opened the mold and manufactured the connectors, which solved the RJ45 boot cracking issue. The revised samples were then sent back to the customer for testing.

3D & Drawings

Before & After

Step 5: Final Delivery

After receiving the revised samples, the customer confirmed that everything was satisfactory. We began mass production, completed the manufacturing and packaging, and arranged shipment to the customer.

Shipment

From design to manufacturing to assembly, we offer a one-stop cabling solution. If you have any custom projects, we’d be happy to hear from you.

✉️：Sales@szangnet.com

Production Line