What is Thermoplastic?

Thermoplastic materials melt and can be reshaped multiple times, making them ideal for cable insulation and jackets in high-volume and automated applications.

Thermoplastics are composed of molecular chains that separate when heat is applied. This allows them to be melted and remolded repeatedly without significant degradation. Common thermoplastic materials include:

• Polyvinyl Chloride (PVC)
• Polyurethane
• Polypropylene
• Tetrafluoroethylene (TFE)
• Fluorinated Ethylene Propylene (FEP)

These materials are lightweight, cost-effective, and often easier to process. Thermoplastics are widely used in cable insulation and jacketing due to their ease of stripping and forming.

What is Thermoset?

Thermoset materials undergo a permanent curing process and cannot be remelted or reshaped, making them ideal for high-temperature and overload-prone circuits.

Thermosets are formed from polymers that are cured through heat, chemicals, or irradiation. This curing process creates cross-linked molecular structures, making the material rigid and heat-resistant. Cross-linked materials are denoted with “XL,” such as:

• XLPE (Cross-Linked Polyethylene)

Common thermoset materials used in wire and cable applications include:

• Natural Rubber
• Styrene-Butadiene Rubber (SBR)
• Ethylene Propylene Diene Monomer (EPDM)
• Silicone Rubber
• Neoprene
• Hypalon

Thermosets are chosen for their ability to maintain structural integrity in high-temperature environments and provide long-term performance in harsh conditions.

What are the key differences between thermoplastic and thermoset materials?

Thermoplastics are reusable and easier to process, while thermosets offer higher heat resistance and better flexibility in cold temperatures.

Understanding the differences is essential for selecting the right insulation or jacket material based on your application’s mechanical, electrical, and environmental demands. Key comparison points include:

• Thermoplastic:
  • Melts and reforms with heat
  • More economical and lighter weight
  • Better electrical properties in many cases
  • Easier to strip and color
• Thermoset:
  • Cross-linked, irreversible structure
  • Higher temperature resistance
  • Better flexibility, even in cold environments
  • Lays flat and handles physical stress better

Choosing the correct material depends on temperature performance, handling requirements, environmental exposure, and long-term reliability.

Need help choosing between thermoplastic and thermoset cable insulation?

Whether you need heat resistance, flexibility, or ease of processing, Allied Wire & Cable offers expert guidance and a wide range of cable solutions. Request a quote today or speak with a specialist to find the best option for your application.