Wire Rope Lanyards

When there’s a fastener, pin, or cap that needs to be removeable, but not go missing, you need a wire rope lanyard. Wire rope lanyards are thin yet strong and durable. They’re more fray resistant and durable than fibrous cords. They can be custom made to customer specifications. Wire rope lanyards are also known as tethers, but no matter what you call them, wire rope lanyards come in handy for a variety of industrial, military and aerospace applications.

These assemblies play a vital role in tethering key components, enhancing safety, being used as support, or maintaining operational efficiency. Although wire rope lanyards may go by different names in the industry, the functionality of them all remains the same, providing a strong and reliable link between two points.

Different components of a wire rope lanyard:        

1. Wire rope or aircraft cable
   One of the main components of a wire rope lanyard. Wire rope is available in different constructions and materials that can apply to many various applications. 1/32”, 3/64”, 1/16”, 3/32” and 1/8” diameters are most common. 7×7 strand is the most common for 1/32” through 3/32” and 7×19 is the most common for 1/8″ and thicker.
2. End Terminals (wire rope end fittings)
   End terminals are permanently fixed to the ends of the wire rope lanyard using swaging, or crimping. Swaged loops, threaded studs, ball ends, and stamped eyelets are a few examples of common end terminals found on wire rope lanyards.
3. Optional wire rope coating
   PVC or Nylon coating (plastic jacketing) provides protection to the surface of the lanyard and can add abrasive resistance for the environment that the lanyard is subjected to. 
4. Hardware Attachments
   These are components that are attached to the wire rope lanyard terminals or loops that provide an additional use for the lanyards for different applications. Some attachments may include mounting tabs, quick links, snap hooks, shackles and pins.

Why Wire Rope Lanyards are practical to many environments and industries due to:

• Offering high strength and durability
• Security 
• Versatility
• Safety enhancer
• Loss prevention
• Tethering

Lanyards (and wire rope in general) combine flexibility with strength, which means they are suitable for static loads as well as dynamic loads. 

Lexco Cable typically assembles wire rope diameters from 1/32” through 1-1/4″. Lanyards are offered in a wide variety of sizes but they are most commonly in sizes 1/32”, 3/64”, 1/16”, 3/32” and 1/8”. Lexco’s sales and engineering team provide high quality customer service while also providing top tier assemblies to industries such as:

• Aerospace 
• Defense
• Marine
• Industrial
• Lifting
• Automotive 

For an overview of common lanyards, visit:
https://catalog.lexcocable.com/viewitems/all-categories/all-categories-wire-rope-lanyards 

The choice of wire rope lanyard termination depends on connections and attachment styles used. From plain loops to loop with mounting tabs to loops with quick release pins, each termination offers a unique advantage to fit, form and function. The most common lanyard termination is a loop or eye, but there are many variations. To review a wider variety of fittings browse our fittings page.

Stamped eyelet (stake eye)
Stamped eyelets (aka stake eyes) are similar to ring terminals. Stamped eyelets are stronger than ring terminals.  Ring terminals are plated copper since they’re intended for electrical cable harnesses.  Whereas stamped eyelets are zinc plated carbon steel or stainless steel.  Also, stamped eyelets are thicker than ring terminals.  Eyelets have a stamped U-channel where the wire rope is machine swaged and stemming from the U-Channel is a stamped flat head with round pin-hole. Lexco Cable machine swages stamped eyelets (aka stake eyes) onto lanyards. The eyelet pin-hole is ideal for installations with a screw, bolt or rivet.

Plain Loop
A simple and common loop formed at the end of a cable. Plain loops are used to attach or connect the wire rope to different components. They are designed to hold the break strength of the wire rope. They can also be reinforced with thimbles to help the plain loop not only maintain its shape by avoiding kinks in the rope but also extending the loop’s lifespan. 

Loop with Mounting Tab
Lanyards with mounting tabs, teardrop, rectangular, or oval shapes are specifically designed for use as an alternative to stamped eyelets. They contain two round pin holes,one for loop connection and the second is for fastener installation. Mounting tabs are typically stainless steel or aluminum.

You can find Lexco’s various mounting tabs here:
https://catalog.lexcocable.com/viewitems/cable-hardware-tools/all-categories-cable-hardware-lanyard-mounting-tab?_ga=2.218440665.190033684.1608191792-1268851337.1602051988 

Loop with Pin Secured
There are multiple pin types that may require a lanyard. Pin examples include detent pins, hitch pins, ball lock pins, lynch pins. These are used for quick release and removable wire rope lanyard connections. The pin mechanism also creates a simplified and reliable process that allows quick and efficient installation and maintenance. 

Loop with Hook
Hooks allow for quick attachment and detachment from other components commonly while providing versatility in lifting, rigging, and safe securing. Typical hooks include snap-hooks and spring-hooks (with or without grommet eye). 

Loop secured to CSP (customer supplied part)
Lexco Cable welcomes customers to furnish components (CSP) for assembly fabrication services.

Selecting the correct wire rope for your lanyard is among one of the most important decisions in the design. Different components can impact performance, strength, and application usage. Understanding the differences and choices that are offered will help ensure that you choose the Lanyard assembly most suitable for your needs.

Commercial Grade Galvanized Steel Aircraft Cable

• Cost efficient solution for a wide range of general industrial applications
• Galvanized (zinc coated) cable suggested for indoor or dry applications
  
• Available in pvc jacketed,nylon jacketed, or unjacketed
  

Commercial Grade Stainless Steel Aircraft Cable

• Better corrosion resistance for outdoor or wet applications
• Moisture protection makes it good for areas where the wire rope will be exposed to more humidity 
• Available in pvc jacketed,nylon jacketed, or unjacketed 
• Good for long term use and maintaining a clean appearance 

Military Specification Galvanized Steel Aircraft Cable

• Manufactured per MIL-DTL-83420 Composition A
• High consistency in performance and construction
• Enhanced traceability
• Reliability in demanding conditions
• Available in unjacketed Type I or jacketed Type II

Military Specification Stainless Steel Aircraft Cable

• Manufactured per MIL-DTL-83420 Composition B
• Common in aerospace and defense applications
• Durability and strength allow for both long term use and different demanding applications
• Available in jacketed  or unjacketed Type I or jacketed Type  II

For more detailed guidance, refer to Lexco’s military lanyard guide:
https://www.lexcocable.com/wp-content/uploads/2024/08/lexco-cable-military-lanyards-guide.pdf

Wire rope lanyards are more than just wire rope connectors, they are used in a wide variety of real world applications where failure and breakage isn’t an option, reliability and durability are crucial. Lanyards provide users with loss prevention, improved safety, and versatility.

Dust Cap Lanyards for Hydraulic Quick-Connect Fittings and Optical Protection

Dust cap lanyards are used to keep dust caps attached to hydraulic quick connect fittings. They are used with strong materials that are used to withstand contamination while also preventing misplacement. When keeping the cap on while not in use, it helps protect the hydraulic quick connect fittings from dirt and moisture, reducing overhead cost and the risk of equipment failure in the long run. They can also be used for optical protection, like scopes, providing shielding for optics from dust, rain, scratches, and much more. Additionally, this creates ease and convenience as the dust cap cannot be easily lost, reducing the amount of tools needed overall and making the processes more efficient. These dust cap lanyards can be used in a multitude of industries, making them very versatile and a great addition to have. 

Valve Cap Retention Lanyards

Lanyards can also provide security for valve caps by ensuring the valve cap remains in the same area when the valve is in use or open. Some of the applications that relate to this would be tire systems in automation, high risk environments in construction zones, and industrial settings where it can be used as a failsafe. This also helps reduce downtime and improve operations processes. 

Marine and Aerospace applications

Marine and aerospace industries are unique with their harsher environments that are exposed to liquids, extreme weather, and stricter requirements. Lanyards provide essential corrosion resistance that can be used to secure equipment to decks and can be used as an essential tool for divers and their equipment allowing it to always remain with divers. In aerospace, lanyards can provide security and are a supplementary tool for preventing foreign object damage.  With these lanyards, they can provide more safety, reliability, and peace of mind when using different equipment. On top of this, they can be personalized to fit any specific marine need big or small.

When deciding on wire rope lanyards, quality and customization matters. Lexco Cable specializes in custom assemblies, allowing engineering and salesmen to help you with your specific lanyard needs. From your initial concept to production, the Lexco team is ready and capable to work closely with you to ensure your lanyard needs are exceeded. Lexco is equipped with the advanced testing capabilities and strong commitment to quality to keep up with any project demands ranging from simple commercial applications to very regulated industry needs.

Key questions to consider when choosing wire rope lanyards:

Does your wire rope lanyard have a tight tolerance?

Please call out critical dimensions and tolerances. Lexco’s assembly production is very experienced in such projects. We at Lexco Cable understand that consistency is crucial, and will ensure that your fit and function will not be compromised. 

Do you require bag & tag labeling? Do you require individual part marking?

Either way Lexco Cable can accommodate, including laser etching capability. The Lexco team will provide clear, durable, and compliant identification for traceability or inventory management.

Does your lanyard have a strength requirement?

If so, Lexco Cable can accommodate. Lexco Cable can proof-load or destructive pull-test your wire rope lanyard to ensure specifications are met.

Does your lanyard require a FAI (first article inspection), PPAP or AS9102?

The Lexco team can help select the appropriate components to expertly ensure longevity and durability in your specific condition. 

Wire rope may be one aspect of manufacturing, but they contain a significant impact in the industry. Not only does it provide safety, but these assemblies are essential across many different manufacturing industries. 

For high quality, customizable, and premium lanyards, Lexco provides a vast variety of Lanyards designed to meet the current demands of everyday applications. Lexco Cable is always interested in reviewing special assembly customer requests. Whether you need your wire rope lanyards to be all type 316 stainless for a marine application, or if you need a non-magnetic lanyard for an electronic sensitive application, or you need a unique termination, we look forward to hearing about your project requirements. We’re easy to get a hold of at Sales@lexcocable.com or https://www.lexcocable.com/contact/.