Leading manufacturer of flexible cables

Flexible cables – also known as continuous flex cables or dynamic cables – are products designed and manufactured specifically for applications with small bend radii requirements combined with the ability to resist physical and mechanical stress such as abrasion, flexing, torsion and bending stresses.

Flexible cables are typically used for applications which are required to move or have moving parts where the requirement for the cable is to withstand demanding stressors. They are specially designed to withstand constant motion and bending without breaking or degrading. As an example, you would find these cables installed inside cable carriers used for controlling robotics. Take a look at our robotic cables page to learn more about this application and product.

Our flexible cable range is ideal for use within the automation, industrial, instrumentation and military sectors providing high quality and highly flexible robust solutions. This cable type is commonly found in automation, robotics, CNC machines, and other moving equipment where standard cables would quickly fail due to mechanical stress. They are also used in medical equipment, where flexibility and precision are a top priority.

To create a highly flexible cable, the design and material selection is critical in ensuring that the product can withstand continuous flexing, abrasion, bending and torsional forces.

Typical construction of a flexible cable includes an inner core of fine-stranded copper conductors, which offer a lot of flexibility and are resistant to fatigue. The inner workings of the core allow the cable to bend without breaking. Around the core, there is specialist insulation, which can withstand bending and abrasion. Some flexible cables offer another layer of shielding, which protects the cable from electromagnetic interference. The outer jacket is made of tough, flexible material – protecting the inside of the cable while still offering flexibility.

We have developed strict cable design guidelines which ensure long life. These guidelines are based on years of trialling products incorporating specific twist lengths and twist directions combined with the right selection of high quality materials to provide a product built to last.

Flexible Flat Cables

As well as our range of flexible cables designed for robotics, machinery and medical uses, we also manufacture a range of Flexible Flat Cables (FFC). FFC is a type of cable that consists of flat, thin conductors, embedded within a flexible plastic film (usually polyester). It’s designed for tight spaces and has extremely high flexibility. Flexible flat cables are commonly used in laptops, printers, cameras and mobile phones.

Flexible flat cables are ultra-flexible, making them perfect for tight-space uses such as in mobile phones and laptops. They are incredibly thin and lightweight, meaning they save a lot of space in compact devices. The parallel layout of flexible flat cables means that electromagnetic interference is significantly reduced. However, they can tear easily and they’re not as durable as other flexible cables, so it’s important to choose the right cable for what you need.

Using Flexible Cables

There are many advantages to our range of flexible cables. They can endure millions of bending cycles without failure, as their specialist design means that bending won’t result in the inner core being broken. These highly durable cables mean that cable breakage happens a lot less. The flexible cable trunking is highly protective, meaning that they can resist everyday wear and tear as well as oil and other byproducts of industrial conditions. Flexible cables are incredibly durable and long lasting.

We have a wide range of flexible cables available, in shielded and unshielded versions. If you need your cable to have more protection, our range includes armoured flexible cables that provide flexibility as well as protection – perfect for use outdoors. If you’re looking for armoured cables or outdoors flexible cables, contact our sales team – we can help you find the right cables for your application!

Our cables are also available to withstand a wide range of conditions and settings – for example, we have an arctic flexible cable that is able to withstand huge drops in temperature. This allows them to be used in a myriad of different settings. They’re also available in a wide range of sizes, from 2mm to 6mm flexible cables. If you need a specific size cable, here at Custom Designed Cables we specialise in providing the right cable size and durability for what you need.

We design and manufacture a wide range of flexible cables, contact us now to discuss your requirements.

Our excellent customer service and fast turnaround times are the cornerstone of the service that we offer. We maintain constant communication with our clients throughout each project to ensure that all products are delivered on time and to the highest quality standard, even for the most challenging deadlines.

In addition to exceptionally fast turnaround times and high-quality cable construction, we offer:

• Full adherence to cable industry standards
• Access to a comprehensive material and component library
• Free consultation and advice

Contact us today to get a quote for your flexible cable requirements.

Frequently asked questions about flexible cables

What is a flexible cable?

Flexible cables, sometimes known as continuous flex cables or dynamic cables, are products designed and manufactured specifically for applications with small bend radii requirements. They must also have the ability to resist physical and mechanical stress such as abrasion, flexing, torsion and bending stresses. Flexible cables are specially designed to withstand constant motion and bending without breaking or degrading. For example, flexible cables are commonly used in robotics, automation, industrial, medical and military sectors. Flexible flat cables are somewhat smaller, and are often used in devices such as laptops, printers, and mobile phones.

Where is flexible cable used?

You can most commonly find flexible cables in automation, robotics, CNC machines, and other moving equipment where standard cables would break due to the mechanical stress. Flexible cables are highly durable, and need to withstand constant motion and bending. They are also commonly used in medical equipment, where flexibility and precision are a top priority. Flexible flat cables are often used in manufacturing technical home goods, such as laptops and mobile phones.

What is the difference between flat cable and flex cable?

There are two types of flexible cables – ordinary and flat flexible cables (FFCs.) Flexible cables are designed for robotics, machinery and medical uses and are highly durable. This means they can be used in extreme environments, and withstand a lot of bending. However, flexible flat cables are smaller, and used in tight environments. They are less durable than regular flat cables, but can be used in smaller environments. FFCs are most commonly used in laptops, mobile phones and printers. If you’re not sure which type of flexible cable you need, get in touch with our sales team and we can help you choose the best cables for you!

What is a 2.5 mm flex cable used for?

Here at Custom Designed Cables, we manufacture our flexible cables in a lot of different sizes, so you can find the most suitable cable for your industry needs. 2.5mm flexible cables are normally used in electrical installations to connect appliances, lighting circuits, and other equipment where flexibility is incredibly important. However, we also manufacture all different sizes of cables, including 4mm and 6mm flexible cables. If you need a specific size of cable for your project, make sure to get in touch with us and we can help you with our custom designed flexible cables!

Can you use flexible cable outside?

Our range of cables includes a large range, including flat and outdoor flexible cables. Flexible cables can endure a lot of bending cycles without breaking, as their specialist design means that bending won’t result in the inner core being broken. Flexible cable trunking is highly protective, meaning that they can resist everyday wear and tear, as well as oil and other byproducts of industrial conditions including weather conditions. Our flexible cables are incredibly durable and long lasting, and can come with extra shielding, so they can be used outdoors. If you’re looking for armoured or outdoor flexible cables, contact our sales team – we can help you find the right cables for your application!