In an era demanding high flexibility, durability, and conductivity, GRL’s custom copper stranded flexible cables stand out as a cornerstone of reliable electrical connectivity. Engineered for dynamic and high-vibration environments, these cables combine the intrinsic benefits of copper with advanced manufacturing techniques to deliver unmatched performance across industries.
GRL Custom Copper Stranded Flexible Cables: Technical Superiority and Versatile Applications for Modern Industries
Technical Advantages of Custom Copper Stranded Flexible Cables
Enhanced Flexibility and Fatigue Resistance
– Multi-Strand Design: GRL’s cables use finely stranded copper conductors (up to 2,000+ strands) to achieve bend radii as low as 5 X cable diameter, ideal for robotics, automated machinery, and repetitive motion systems.
– Cycle Life: Tested to withstand 10 million flex cycles without conductor breakage (IEC 60228 Class 5/6 standards), outperforming solid-core alternatives.
Superior Electrical Performance
– Conductivity: 98% IACS (International Annealed Copper Standard) ensures minimal resistive losses—critical for high-current applications like EV charging (up to 500A continuous).
– Skin Effect Mitigation: Stranded designs reduce AC resistance at high frequencies (e.g., 50–60 Hz), lowering energy loss by 15–20% compared to solid conductors.
Environmental Durability
– Temperature Range: -60°C to +200°C operation with silicone or PTFE insulation, suitable for aerospace or foundry equipment.
– Corrosion Resistance: Tin-plated or silver-plated strands (optional) prevent oxidation in marine or chemical-heavy environments (ASTM B117 salt spray tested for 1,000+ hours).
Customization Capabilities by GRL
Conductor Design
– Strand Count & Gauge: From ultra-fine 0.05mm strands for medical devices to heavy-duty 4/0 AWG for industrial welding machines.
– Lay Direction: Optimized helical lay configurations (e.g., unilay, concentric) to minimize torque and cable “memory.”
Insulation & Jacketing
| Material | Key Properties | Applications |
| Silicone | High heat resistance, flexibility | EV battery packs, foundries |
| TPE/TPU | Abrasion resistance, oil/chemical proof | Robotics, offshore rigs |
| FEP/PTFE | Ultra-low smoke, flame retardant (UL 94 V-0) | Aerospace, data centers |
Termination Solutions
– Custom Connectors: Laser-welded lugs, M8/M12 circular connectors, or PCB-mount terminals.
– Shielding: Braided copper or foil shielding for EMI/RFI-sensitive applications (e.g., medical imaging, military comms).
Industry-Specific Applications
Renewable Energy Systems
– Solar Trackers: Flexible cables withstand daily 180° rotations and UV exposure (IEC 62930 compliant).
– Wind Turbines: Torsion-resistant designs for yaw/pitch systems in -40°C Arctic conditions.
Electric Vehicles (EVs)
– Battery Interconnects: High-current (600A+) silicone-insulated cables with UL 62 certification.
– Charging Guns: Compact, liquid-cooled cables for 350 kW DC fast chargers.
Industrial Automation
– Robotic Arms: Continuous flex cables for 6-axis robots (ISO 9409-1 compliance).
– CNC Machines: Oil-resistant TPU jackets for cutting fluid exposure.
Aerospace & Defense
– Avionics: MIL-DTL-22734 compliant, lightweight cables for cockpit systems.
– UAVs: High-strength aramid-reinforced cables for drone propulsion.
Medical Equipment
– MRI Machines: Non-magnetic, copper-nickel alloy strands for zero interference.
– Surgical Robots: Sterilizable (autoclavable) cables with PTFE insulation.
Compliance and Testing
– Standards: UL 62, IEC 60228, RoHS 3, REACH.
– Testing Protocols:
– Flex Life: 50,000+ cycles @ 1 Hz (EN 50396).
– Voltage Withstand: 3.5 kV AC for 5 minutes (IEC 60502-1).
– Flame Resistance: Passes FT4/IEEE 1202 vertical tray test.
How to Select the Right Stranded Copper Cable
- Current Load: Use the formula:
- Custom Copper Stranded Flexible Cables Environmental Factors:
– Temperature: Derate ampacity by 20% for every 10°C above 30°C.
– Chemical Exposure: Opt for FEP or TPE jackets in corrosive settings.
Maintenance Best Practices
– Inspection: Check for strand breakage using micro-Ohm meters (resistance increase >10% indicates wear).
– Routing: Use IGUS® energy chains to avoid sharp bends.
Why Choose GRL?
– Rapid Prototyping: 2-week lead time for custom samples.
– Certifications: UL, CE, TUV, and ISO 9001:2015 manufacturing.
– Sustainability: 100% recyclable materials and RoHS-compliant processes.
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GRL’s Custom Copper Stranded Flexible Cables are engineered to meet the evolving demands of modern industries, offering unparalleled flexibility, durability, and efficiency. By partnering with GRL, businesses gain access to tailored solutions that reduce downtime, enhance safety, and comply with global standards.
Visit product Copper Stranded Flexible Connection
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