Cables for the Harshest Underwater Environments

When failure isn’t an option, you need more than a cable supplier—you need an engineering partner. Mercury Wire designs and manufactures custom submersible cable assemblies engineered for continuous submersion and long-term performance in demanding underwater environments.

Our assemblies are built to withstand the real-world challenges of submerged applications, including hydrostatic pressure, abrasion, chemical exposure, moisture ingress, and repeated flexing. Every solution is engineered specifically for your system, with careful consideration of conductor selection, insulation materials, sealing methods, shielding, jacketing, and termination design to ensure consistent electrical and mechanical performance.

For more than 50 years, Mercury Wire has partnered with OEMs and industrial manufacturers to develop application-specific cable assemblies for marine systems, wastewater infrastructure, and other submerged industrial environments where reliability is critical.

If your equipment operates in harsh, corrosive, or constantly wet conditions, Mercury Wire delivers the custom-engineered cable solutions needed to keep your systems performing reliably below the surface.

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.
  • Proven Industrial Performance
    Designed to withstand abrasion, flex, heat, chemicals, vibration, and harsh environments. 

Engineered for Demanding Applications

We support critical systems including: 

• ROV tethers and umbilicals 
• Subsea communication and instrumentation
• Underwater power distribution
• Environmental monitoring systems
• Pipe and sewer inspection equipment
• Wastewater treatment and analysis systems
• Buoyancy-controlled and towed cable arrays
  

Design Challenges We Solve

Harsh environments expose weaknesses fast. We engineer to eliminate them.

• Premature cable failure in wet or corrosive conditions
• Abrasion and tensile stress in dynamic applications
• EMI/RFI interference and signal integrity problems
• Tight routing and complex installation constraints
• Identification and traceability challenges

From conductor selection to shielding, jacketing, and strain relief, every component is specified for your exact application, not pulled from a catalog.

Full Custom 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, and potting
• Short-run prototyping and scalable production
• In-house testing and validation
• Quality assurance program support

No compromises. No generic assemblies. Built specifically for your system.

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