Custom Wire & Cable
Galaxy can design and provide cable constructions from the simplest cable to the most unique and challenging design.
Custom Cable Design Factors
There are a number of factors that are important to consider when designing a custom cable. One of the most important things to consider is the environment in which the cable will be used. Will the cable be exposed to chemicals? Perhaps it’s going into a rugged environment, and needs to have good abrasion resistance. Selecting a cable jacket that takes into account the environmental conditions where it will be used is critical in the performance, and potentially the viability, of the cable itself.
The overall size requirements or limitations of the cable are sometimes overlooked. There are some applications where a cable is installed in a fixed location, and will not move. However, it may be routed in a way that flexibility is important for the installation process. If flexibility is critical, simple things like increased strand count and spiral shields will aid in the performance of the cable. Understanding the electrical requirements is critical when it comes to designing a cable. Not only is voltage important to know, but other requirements such as impedance and capacitance need to be evaluated to determine the right type and amount of insulation. It’s advised to consider all of these at the time of design.
Galaxy’s experience and expertise can be utilized to make sure these factors are considered, and important requirements are not overlooked.
Custom Cable Options & Materials
Conductor Options
Custom cable and wire from Galaxy can be supplied with many different conductor options, each with different physical and electrical characteristics. Design factors to consider include minimum and maximum temperatures, maximum voltage, and DC resistance of the insulation, as well as the conductor, size limitations, tensile strength and working environment.
Shielding Options
Custom cable and wire from Galaxy can be supplied with many different shielding options, each with different physical and electrical characteristics. Design factors to consider include for shielding include materials, construction, temperature and flexibility.
Enhancement Options
Custom cable and wire from Galaxy can be supplied with many different enhancement options based upon the desired use and functionality of the custom wire or cable. Galaxy offers custom wire and cable with enhancement options that include: strength members, water blocking, fillers, rods, and tubes/breather tubes.
Insulation & Jacketing Materials
Galaxy is a leading manufacturer and supplier of standard/stock and custom wire and cable with a wide variety of material choices for the jacket and insulation. The selection of wire/cable insulation material and jacketing compound are critical to the successful use of the wire or cable in its application.
Custom Cable Options and Materials
| Conductor Options | Shielding Options | Enhancement Options | Insulation & Jacketing Materials | Insulation & Jacketing Materials |
|---|---|---|---|---|
| Bare Copper | Bare Copper Braid | Strength Members | CPE / Chlorinated Polyethylene | PFA / Perfluoroalkoxy |
| Tinned Copper | Tinned Copper Braid | Water Blocking | EPDM / Ethylene Propylene Diene Monomer | PFE / Perfluoroelastomer |
| Silver Plated Copper | Silver Plated Copper Braid | Fillers | ETFE / Ethylene Tetrafluroroethylene | PP / Polypropylene |
| Nickel Plated Copper | Nickel Plated Copper Braid | Rods | FEP / Fluorinated Ethylene | PTFE / Polytetrafluoroethylene |
| High Strength Alloys | High Strength Alloys Braid | Tubes | Foamed FEP | PUR / Polyurethane |
| Copper Clad Steel | Copper Clad Steel Braid | Foamed PFA | PVC / Polyvinyl Chloride | |
| Prebonded Conductor | Stainless Steel Braid | Foamed PE | Silicone | |
| Overcoated Conductor | Aluminum Mylar Foil Shield | Foamed TPE | Tefzel® | |
| Topcoated Conductor | Spiral Shield | Halar® | TFE / Tetrafluoroethylene | |
| HDPE & LDPE | TPE / Thermoplastic Elastomer | |||
| Hytrel® | TPR / Thermoplastic Rubber | |||
| mPPE / Modified Polyphenylene | XLPE / Cross-Linked Polyethylene | |||
| Neoprene | XLPO / Cross-Linked Polyolefin | |||
| PE / Polyethylene |
Request a Quote for Custom Wire & Cable
Galaxy regularly works with customers to change an existing cable or design a brand new product, from the very beginning stages of the cable design through production and beyond. Galaxy’s diverse capabilities can be utilized for any custom cable requirement.