Festoon cables are flat flexible cables often used cranes, hoists, festoon systems, and other suspension applications. They are typically made with PVC or neoprene jacketing and insulation. They are ideal for use in applications where flexibility is important. Flat festoon cables are often found in construction or industrial applications that require temporary power and need a durable and flexible cable to hold a large weight.

Because of its flat construction, festoon cables are mostly chosen in applications where there is constant flexing since the cable will not coil. Flex cables don’t always come in the flat shape that festoon cables have, but are always used in flexing applications that require constant movement and UL/CSA approvals. Sometimes a standard flat flex cable doesn't meet an application's required specifications, so a custom flat festoon cable is needed.

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Our Custom Festoon Cable Solution

An Allied Wire and Cable customer that specialized in aircraft parts needed a flexible cable to be used in an airport bridge. Airport bridges are portable connectors that directly attach terminal gates to planes so that passengers do not have to go outside to get on their flights. Since these connectors were constantly being moved and reshaped, the flexibility of this custom cable was one of the customer’s main concerns. When they couldn't find a cable that worked for their application, they knew it was time to contact us for help designing a custom cable.

This custom flat, high flex festoon cable was designed with four conductors made of soft-drawn bare-copper conductors. The conductors in this flat flex cable were made with Class K stranding. Class K conductors feature high strand counts, which gives them high flexing abilities. Three 4/0 AWG conductors were combined with one 2 AWG conductor under a single jacket for this flexible cable.

Keeping the customer’s flexibility concerns in mind, our custom cable experts decided neoprene would be the best jacket material due to its physical toughness and high flexing abilities. Even though many festoon cables feature PVC insulation, we knew it wasn't ideal for this flat flexible cable. Combining the different conductors under a single jacket to make a composite flat flex cable helped the customer optimize space in their application. This flexible cable also met CSA specifications.

This customer was highly satisfied with their custom flat flexible cable and the customer service they received. If you need a custom flexible cable or even a festoon cable printed with custom markings, let Allied Wire and Cable help. We are a supplier and manufacturer of custom cables for a wide variety of industries. To get started, visit our Custom Cable Design Center or Contact Us today!

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