Submarine & Submersible Cable Assemblies

Mercury Wire designs and manufactures custom submarine and submersible cable assemblies engineered for reliable performance in high-pressure, corrosive, and continuously wet environments. Our cables are built to maintain electrical integrity and mechanical durability in demanding underwater applications where long-term reliability is essential.

From saltwater and offshore deployments to wastewater treatment and submerged industrial infrastructure, each cable assembly is engineered to meet precise electrical, mechanical, and environmental requirements. Our team works closely with OEMs and system designers to specify the right conductors, insulation systems, shielding, jacketing materials, sealing methods, and terminations needed to ensure dependable operation below the surface.

Unlike off-the-shelf options, Mercury Wire’s submarine cables are designed specifically for your application, not adapted from a catalog. The result is a purpose-built cable solution capable of withstanding pressure, corrosion, moisture ingress, and continuous submersion while maintaining consistent performance in the field.

Whether supporting offshore systems, subsea instrumentation, or submerged industrial equipment, Mercury Wire delivers the engineering expertise and manufacturing precision required for cable assemblies that perform reliably in the most challenging underwater environments.

Why Mercury Wire  

• Custom Cable Engineering
  Built to your exact conductor, gauge, insulation, shielding, and jacket requirements.
• Proven Industrial Performance
  Designed to withstand abrasion, flex, heat, chemicals, vibration, and harsh environments.
• Reliable Lead Times
  Fast prototyping and production support to keep your projects moving.
• Tight Tolerances & Compliance
  Consistent, repeatable quality you can specify with confidence.
• OTIF Delivery
  On-time, in-full manufacturing you can plan around.

Applications We Support    

Our submarine cable assemblies are used in critical systems where failure is not an option:  

• • Remotely operated vehicles (ROVs) and tether systems
  • Subsea power distribution and instrumentation
  • Underwater communication and surveillance systems
  • Towed and moored cable arrays
  • Push-rod and robotic pipeline inspection systems
  • Wastewater and treatment facility equipment
  • Environmental monitoring and sensor platforms

Each assembly is engineered to withstand hydrostatic pressure, abrasion, tensile stress, chemical exposure, and dynamic flexing.

Design Challenges We Solve

Underwater environments expose weaknesses quickly. We engineer cable systems to eliminate common failure points before they become field problems.

• • Mechanical Challenges
    Abrasion and tensile stress in dynamic applications
    Flex fatigue in tethered or mobile systems
    Strain concentration at termination points
  • Electrical Challenges
    EMI/RFI interference
    Signal degradation over distance
    Power stability in high-load system
  • Environmental Challenges
    Water ingress and long-term submersion
    Chemical exposure in treatment and sewer systems
    Pressure-related insulation breakdown

When performance and reliability are mission-critical, our engineering team ensures your assemblies meet stringent design and validation standards before they ever reach the field.

Full Custom Subsea Cable Assembly Capabilities

We control performance from concept through validation:

• • Custom conductor, gauge, insulation, shielding, and jacketing
  • Connector and fitting selection
  • Injection molding and mold design support
  • Termination, crimping, soldering, epoxy sealing, and potting
  • Overmolding and strain relief solutions
  • Short-run prototyping and scalable production
  • In-house testing and validation
  • Quality assurance documentation support

No generic assemblies. No design compromises. Every build is application-specific.

A Long-Term Engineering Partner

We work directly with your engineering, operations, and procurement teams to ensure manufacturability, reliability, and predictable delivery. Responsive prototyping. Tight tolerances. OTIF performance you can plan around. If your project demands a rugged, custom-engineered cable solution for underwater or wet environments, let’s build it right the first time.

Built for Performance. Backed by Standards

Mercury Wire adheres to rigorous engineering and compliance standards to ensure long-term reliability. Our certifications and compliance programs include:

• REACH and RoHS compliance
• UL and CSA approvals (application-specific)
• IPC-A-620 certification
• ITAR registration
• Comprehensive in-house testing and validation