Custom cable in motion
Bend radius in custom cables — what it is, why it matters and how improper bending can impact performance and lifespan. Learn how to determine the correct bend radius for your application and ensure reliability, flexibility and safety in cable design, installation and long-term use

Ultra Flexibility = Custom Solutions
The difference between adequate and ideal
We'll connect you with a wire expert who can help.
While it is often one of the last characteristics mentioned, flexibility is an important design consideration for many wire and cable applications. Other aspects such as number of conductors or voltage rating are essential to designing an adequate construction, however, for many multi-conductor cables, the difference between adequate and ideal comes down to flexibility.

Off-the-shelf multi-conductor cable will typically utilize solid or coarsely stranded conductors, stiff insulation, separation layer materials, and foil shielding to cut costs. For applications in which flexibility is not an afterthought, a custom solution is often required. New England Wire Technologies specializes in designing and manufacturing flexible multi-conductor cable tailored to your specific requirements.

Design Methods:

• Miniaturization
• Flexible Stranding
• Thin wall/flexible insulating compounds and barrier layers
• Fine wire shields

Typical Applications:

• Robotic or high speed machinery
• Aerospace
• Test and measurement
• Miniature relays
• Medical: hand-held medical devices, electrosurgical devices, patient monitoring, internal body imaging

Advantages:

• Ease of routing in tight spaces
• Reduced effect on sensitive equipment and instruments
• Comfort and ease of use for operator of handheld devices
• Improved flex-life

Learn more about our ultra flexible stranding options, custom flexible interconnects, and extended flex-life cables.

Do You Need Custom Cable?
A common question asked of the sales and engineering staff at New England Wire Technologies by those unfamiliar with our company is why a custom cable solution should be considered when there are so many off the shelf options out there. This is a very reasonable question and in some cases a standard product does make sense. However, when electrical device and component manufacturers stop to consider what properties would be ideal to meet the demanding requirements of their application and what level of service and quality they expect from their suppliers, the advantage of a custom cable solution from New England Wire Technologies becomes apparent.

The most immediate benefit of a custom solution is the knowledge and design assistance that the staff at New England Wire can provide for your project. Rather than spending days or weeks researching material, electrical and mechanical properties to understand your design options and then pouring through catalogs or calling vendors to try to find a part number close to what you actually need, you can simply go to our Contact Us form to upload a document, describe your requirements, or send an image of an existing cable. Our engineering staff will use their knowledge and experience to design an ideal solution optimized for your exact application. When new requirements, additional options, or added capabilities become necessary, a custom option is quickly adaptable to your changing needs.

Every aspect of a cable is customizable. A standard product will often use coarse stranding, stiff insulation and shielding, and low temperature materials to reduce cost. In addition, the exact size, number, or composition of components needed may not be an option, limiting your selection to an oversized, overweight, or otherwise inexact solution. With a custom cable from New England Wire Technologies you can select the exact components needed for your application to minimize size and weight. We will work with you to determine appropriate conductor stranding for the level of flexibility needed and the ideal conductor material or plating option to balance conductivity, flex life, temperature rating, etc. New England Wire stocks over one hundred extrusion compounds for use as insulation and cable jacketing, combined with a variety of film and textile options to support an incredible range of product requirements. These include the specific temperature and voltage ratings required for your application, flame resistance, flexibility, biocompatibility, low smoke, chemical resistance, toughness, UV resistance, and many more. Shielding is also customizable with the proper selection of braided, spiral, foil, or a combination to balance electrical shielding effectiveness with mechanical or diameter requirements. These are just a sampling of the design options and potential advantages that a custom cable solution from New England Wire Technologies can provide.

Why a custom cable? Perhaps that is a question best answered by the thousands of satisfied customers around the world using New England Wire products. Whether it is the right option for you; that is a question we would love to help you figure out…contact us today to discuss your wire and cable needs.