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custom composite power cable

Composite power cables serve a multitude of purposes in even the most strenuous environments. These cables are strong and durable and can withstand abuse from the elements for long periods of time, ensuring that they remain functional in the toughest of climates. When an application requires a wire to meet a certain standard, a custom power cord is needed. However, some applications have limited space and need many cables grouped together into one configuration, so a custom composite cable is needed.

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Our Custom Power Cable Solution

One customer came to Allied Wire and Cable with a design and confidence, knowing we would help them since we had designed custom cables for them in the past. This time, the custom power cable we were asked to manufacture was for a piece of oil field equipment. The custom composite power cable would be run from a control panel to a tool that could produce high temperatures and carry a high voltage. Since this cable needed to serve multiple functions and needed a longer cable length, this customer knew a custom cable was the way to go.

The custom power cord's specifications called for two 10 gauge power wires with four, smaller data wire pairs of different gauge sizes. All of the conductors were made of tinned copper and insulated with FEP. In addition to its wide operating temperature range, FEP insulation is also resistant to solvents, acids, alkalis, ozone, and oils— an important characteristic in many pipeline projects.

These pairs were bound together under a thermoplastic elastomer (TPE) jacket, which was moldable and retained the flexibility and stretch of rubber. TPE is not typically used for heat or chemical resistance, but since the jacket would be stripped back and away from the heat, this durable material was a suitable option.

The customers' assigned Allied Wire and Cable sales representative had only one suggestion to improve the design of this custom power cord: to use stranded conductors instead of solid so that the flexibility of the conductor would match that of the insulation and jacket. The customer agreed, and the custom configuration was adjusted before the order was finalized. From there, the sales representative was able to expedite the power cable manufacturing process to meet the demands of the customer’s tight schedule.

Sometimes an application has limited space but needs multiple cables to perform different functions. Allied Wire and Cable is a leading manufacturer of custom cables. Do you have a custom cable already designed and need suggestions? Allied Wire and Cable can help. Visit our Custom Cable Design Center or contact us today to get started. Need something extra for your cable but don't need an entirely custom product? View our wide selection of value-added services and Cable Sleeving options.

Send us more specifications for your custom Composite Cable  using our Create-a-Cable form in our custom cable design center. 

Customize Composite Cable