Key to High Flexibility in Wires

 

Wiring is undoubtedly a part of one’s everyday life. Wires are a part of your work and home, used in telecommunications, and even safety equipment. In addition to everyday applications of wire, they are also used in a variety of professional industries. Things like surgical handpieces, telescopes, and electronic testing devices are all operational with the help of wires. One of the major factors when it comes to the lifespan and effectiveness of wires is flexibility. Below you will find the key to high flexibility in wires. 

Key to High Flexibility in Wires

Industrial wire is commonly made up of multiple wire strands. These are referred to as “base strands.” Multiple strands make the wire more flexible than if it was just one solid piece of metal. The base strands allow the entire wire to bend and flex much easier. When it comes to flexibility, the finer the base strand the better. Finely stranded wires also have a much longer lifespan. In addition to finer base strands, the amount is also a factor when it comes to flexibility. Wires can have between 7 to 66 base strands depending on the type. There are a number of benefits when it comes to wire flexibility, especially in regard to its lifespan.

Benefits of Wire Flexibility

Wire flexibility offers a number of benefits. In fact, it can reduce energy consumption, weigh less, and take up less space. Because most wire applications require use 24/7, the repeated motions can put stress on most wires. These are often automated machines that require reliability and effectiveness. With that, low-quality, inflexible wires can cause a variety of issues that can be expensive and time-consuming. Industry research found that more than half of the quality and reliability issues in automated equipment is the result of poor wiring and cabling. This demonstrates both the importance and benefits of wire flexibility in all applications. 

Quality Wire Factors

There are a number of factors that impact the lifespan of a wire.

• Bend Radius: This is the measure of the inside curvature of a wire. The bend radius is the minimum radius one can bend a wire without damaging it or shortening its lifespan.
• Flexing Capabilities: The flexing capability of a wire depends on the amount of base strands. In addition, the size of the base strands is a factor as finer wire has a significantly lumber lifespan. This is especially true in applications that require continual flexing.
• Environmental Factors: Temperature changes and moisture are both environmental factors that can impact wires.

Ultraflexible Wire and Cable Customization

The importance of ultraflexible wire and cable is clear. The flex life alone demonstrates why flexible wire is a top priority in any application. Standard wire has an average flex life of roughly 50,000 cycles. However, ultraflexible cables are designed to complete up to 3 million cycles.

Customizing your cables can make a huge difference in your application. This is why it’s important to consult with a custom wire company as they can design the wire based on your unique needs. Catering the manufacturing specifications can include adjusting the strand configurations, range of conductor materials, wire gauge sizes, insulation wall thickness, shield materials, and jackets. 

Calmont Wire and Cable

If you need customized wires for your application, contact Calmont Wire and Cable. They are skilled in the design and customization of ultraflexilbe wire. Their team uses conductors with a large number of base strands to create a wire that is flexible with a long lifespan. Providing quality wires that are long-lasting is their top priority. Contact the team at Calmont Wire and Cable today for any of your custom wire needs!