Custom DB78 Cable
- 78-position, four-row high-density D-sub interface
- Male or female DB78 ends in the gender combinations shown below
- PVC-molded, serviceable metal-shell, and bare-wire constructions
- Straight-through or fully custom point-to-point wiring
- Custom shield treatment, cable length, labels, and breakout geometry
- Numbered DB9 branches for multiport breakout applications
- Drawing and pin-map review before custom production
Custom DB78 Cable Assemblies for Dense Industrial I/O
When one connector must carry many independent circuits through a limited panel opening, a custom DB78 cable can simplify the harness and ease field service. The 78-position high-density D-sub interface describes the mechanical connector, not the electrical function: the same shell may carry digital I/O, analog channels, control lines, serial ports, grounds, or a proprietary combination.
BespokeCable builds DB78 assemblies from an approved wiring schedule. Available constructions include PVC-molded DB78-to-DB78 cables, metal-shell versions, labeled bare-wire fan-outs, and DB78-to-8-port or 16-port DB9 breakout harnesses. Send the equipment model, connector views, length, and pinout so we can confirm the production drawing before manufacture.
You can compare smaller connector families in the D-Sub cable collection when the equipment design does not require 78 positions.
DB78 Cable Specifications
| Parameter | Available Choices | Confirmation Needed |
| Main connector | 78-position high-density D-sub, male or female | Mating connector and face-view gender |
| End format | DB78, bare wire, 8 × DB9, or 16 × DB9 | Exact second-end and branch arrangement |
| Wiring | 1:1 or custom | Complete pin table, including unused or tied pins |
| Hood | PVC molded or metal shell | Clearance, cable-exit direction, serviceability |
| Conductors | Selected to match circuit schedule | Signal type, current, flexibility, grouping |
| Shield | Foil, braid, combined, or project-defined | Termination to shell, drain, one end, or both ends |
| Length | Custom | Measuring points and tolerance |
| Identification | Pin labels, branch IDs, OEM marking | Text, color, location, revision |
| Verification | Continuity against approved drawing | Additional project-specific inspection |
The approved quotation and drawing define final materials, dimensions, electrical limits, and compliance requirements.
1# PVC-Molded DB78 Cables
P/N: BC-CBD013-MMP
PVC-molded male-to-male DB78 assembly for two female mating ports. Confirm whether the required wiring is 1:1 or device-specific before ordering.
P/N: BC-CBD013-MFP
Male-to-female molded assembly for extension or equipment interconnects, provided the approved pin schedule and hardware match both ports.
P/N: BC-CBD013-FFP
Female-to-female molded DB78 cable for two male mating interfaces. Gender does not define signal direction or crossover, so supply the pin map.
2# Metal-Shell DB78 Cables
P/N: BC-CBD013-MMM
Serviceable metal hood, male-to-male build for installations that require defined shell bonding, robust retention, or access to the termination.
P/N: BC-CBD013-MFM
Male-to-female DB78 assembly with metal hoods. Specify shield termination, cable diameter, clearance, and exact wiring.
P/N: BC-CBD013-FFM
Female-to-female metal-shell assembly for two male ports, built to the documented circuit map rather than an assumed “null-modem” layout.
3# DB78 to Bare Wire
P/N: BC-CBD013-MT
Male DB78 fan-out with labeled loose conductors for terminal blocks, prototype harnesses, or custom PCB termination.
P/N: BC-CBD013-FT
Female DB78 to identified bare wires. Specify strip length, tinning or ferrules, stagger, labels, and shield/drain finish.
4# DB78 to DB9 Breakout Harnesses
P/N: BC-CBD013-8
Eight-branch DB9 breakout with branch identification. The host-card model and manufacturer mapping must be supplied; no universal 8-port layout is assumed.
P/N: BC-CBD013-16
Sixteen-branch DB9 breakout for a documented multiport host. Define branch gender, labels, lengths, pin groups, and strain-relief geometry.
Confirm the 78 Position Connector and Mating Envelope
A DB78 assembly uses a high-density 78-position D-sub, commonly designated DD-78 or HD78. Confirm the mating connector and contact layout before selecting the cable. A photograph should show the whole shell and fastening arrangement, not only a close crop of the contact field.
The installed envelope includes the hood, screws, and initial cable bend. On a crowded instrument panel, these details can decide whether the assembly is serviceable. When asking us to review a straight cable or a more complex breakout, provide the available space.
Organize the Circuits Before Choosing the Bundle
The number of positions describes connector capacity, not a standard signal assignment. A DB78 harness may carry several defined groups, each with different return, pairing, or shielding needs. List those requirements before choosing wire construction and termination details.
A fully populated design also needs enough space inside the hood to terminate and support the bundle. Larger conductors or additional screens may affect that fit. We review the electrical schedule and mechanical envelope together rather than treating the cable diameter as a detail to resolve after the drawing is finished.
Define What Each DB9 Branch Actually Carries
Eight- and sixteen-DB9 breakouts distribute selected signals from the main connector. They are passive harnesses, not multiport interface electronics. In particular, sixteen nine-position shells do not imply 144 independently wired circuits through a 78-position source connector.
Name each branch and show every populated contact. Any shared return or intentionally unused position needs to appear in the drawing. This makes the branch count commercially useful without suggesting that every visible contact or every conventional serial signal is available on every connector.
Make Dense Harnesses Practical to Install
Bare-wire and multi-branch versions need controlled breakout geometry and correct wiring. Specify where the jacket ends, how long each branch should be, and where the assembly will be supported. Service access can be difficult if you cut every branch to the shortest possible reach.
For a finished DB78-to-DB78 cable, check retention and the space needed to disconnect it. Shield termination, jacket requirements, and environmental limits remain project-specific. Neither contact plating nor screw fastening justifies a blanket promise of interference-free operation or unlimited service life.
Yes, but each version should have its own part number, revision, unit label, quantity, and packaging line, so you can’t mix similar harnesses.
Learn more about what a DB78 cable is.
Specify coil diameter, connector caps, branch restraint, individual bags, desiccant if needed, carton quantity, and whether labels must remain visible without opening the package.
We can discuss serialization or lot marking for OEM programs. Define the identifier format, data file, label location, and retention record before the quotation.
Related Products
Planning the Acceptance of a High Circuit Count DB78 Harness
Give the drawing one source of truth
Use a master connection schedule for the whole assembly. It should connect every source contact to a named destination and identify intentional opens and shared circuits. Keep branch names consistent with equipment labels so the drawing can be used during installation as well as manufacture.
If the design changes, revise the master schedule before issuing revised branch drawings. Independent lists are difficult to reconcile when several nearly identical connectors are involved.
Agree on inspection before the pilot
Decide what evidence is required for correct assembly. The electrical record should correspond to the approved schedule, while the mechanical inspection should cover the dimensions and routing features that matter in the enclosure. Specialized performance requirements need their own agreed method and limits.
Do not confuse cable verification with approval of the equipment design. A harness can match a mistaken schematic perfectly. The equipment owner still needs to confirm the intended signal functions and application behavior.
Exercise the complete installation
Fit all branches and check the assembly with neighboring hardware present. Confirm that fastening, label reading, and removal are possible without straining other connections. Then run the system functions relevant to each signal group rather than testing only the easiest branch.
Keep the accepted sample identity and system configuration with the result. This creates a traceable basis for later production and makes an engineering change easier to evaluate than a request to copy the appearance of an old harness.
