Radiation Resistant Cables
Trusted UK manufacturer of radiation resistant cables
At Custom Designed Cables, we design and manufacture radiation resistant cables for the most demanding environments. Our cables are used in nuclear power plants, defence facilities, research laboratories, aerospace projects, and medical imaging systems.
Radiation resistant cables, also called nuclear cables, must perform safely and reliably when exposed to ionising radiation, high temperatures, pressure, and corrosive fluids.
With decades of manufacturing experience and an extensive library of specialist materials, CDC supplies cables that meet these requirements while supporting long service life and low maintenance.
Why radiation resistant cables are critical
Any component used within a nuclear plant or radiation-intense environment is exposed to harsh conditions:
- Ionising radiation that degrades common polymers.
- Extreme heat from core systems or shielding.
- High pressure in containment areas.
- Exposure to chemicals and oils during operation or maintenance.
If cables fail, critical systems such as pumps, sensors, or emergency circuits could be compromised. This is why every nuclear cable must be designed and built to standards that prioritise safety, durability, and traceability.
Core requirements for nuclear cables
Radiation resistant cables must meet strict performance criteria to operate reliably for decades. The following properties are central to their design.
Fire resistance
Cables must be flame retardant, halogen-free, and maintain circuit integrity even under fire conditions. In the event of a fire, they cannot emit toxic gases that would endanger personnel or damage equipment.
Temperature resistance
Nuclear installations operate at very high internal temperatures. With the right conductor materials, insulation, and jacket compounds, nuclear cables can achieve long-term temperature resistance and lifespans of up to 40 years.
Radiation resistance (MRAD)
Ionising radiation causes rapid breakdown of ordinary plastics and rubbers. CDC uses compounds tested to withstand up to 200 MRAD (2.0 MGy) at Cobalt-60 dosage rates of 0.80 MRAD per hour. This ensures long-term performance for control, instrumentation, and power circuits in nuclear environments.
Chemical and fluid resistance
Cables in containment areas are regularly exposed to oils, solvents, acids, and alkaline fluids. Our radiation resistant cables are tested against:
- Gasoline
- Acetone
- Hydraulic fluids
- Trichloroethylene
- Toluene
- Chlorothene
- 10% sulphuric acid
- 10% sodium hydroxide
- ASTM No. 2 and No. 3 reference oils
Abrasion and mechanical strength
Physical damage during installation or maintenance can compromise cable safety. Selected compounds provide excellent cut-through, tear, and abrasion resistance, so cables remain intact even in areas with high mechanical stress.
Applications of radiation resistant cables
Radiation resistant cables are deployed across a wide range of industries. Each sector has specific systems and conditions where these cables are essential.
Nuclear power plants
Nuclear reactors and supporting facilities rely on thousands of kilometres of cable to control, monitor, and protect core systems. Radiation resistant cables are installed within control and instrumentation circuits, emergency shutdown systems, and reactor monitoring equipment such as temperature and pressure sensors.
As access is restricted and replacement is costly, these cables must operate reliably for decades while resisting radiation, heat, and pressure.
Defence and naval facilities
Military vessels and secure test facilities operate in environments where radiation and extreme conditions are possible. Submarine propulsion and control systems require cables that tolerate high pressure and radiation, while weapons test ranges and monitoring stations depend on shielded communication lines that remain stable in demanding conditions. Here, radiation resistance and electromagnetic shielding combine to ensure uninterrupted operation.
Aerospace and satellites
Spacecraft and high-altitude systems are exposed to cosmic radiation and solar particle events. Standard cabling would degrade quickly, risking mission failure.
- Satellite power and data transmission wiring must perform reliably throughout long missions.
- Avionics systems in aircraft and spacecraft depend on cables with low weight and long service life.
- Instrumentation and payload equipment on scientific probes require shielding integrity and stable electrical properties.
Repair is impossible in orbit, so proven performance is vital.
Medical imaging and therapy
Hospitals and research centres use high-powered imaging and treatment systems that generate radiation. In this setting, cables provide safety and ensure consistent image quality. They are used in MRI and PET scanners to connect sensors and imaging coils, and in radiotherapy machines where control and safety systems must perform reliably under exposure.
Research laboratories and accelerators
High-energy physics and nuclear research facilities operate with particle beams, reactors, and test chambers that generate intense radiation. Cables within these laboratories power supply and diagnostic systems, support experimental reactors, and link radiation testing chambers where new materials and components are evaluated. They must handle repeated cycles of high exposure while maintaining stable electrical characteristics for sensitive experiments.
Materials and compliance standards
Radiation resistant cable performance depends on both material selection and manufacturing processes. At CDC we offer:
- Insulations and jackets: cross-linked polyolefins, fluoropolymers, silicone, and other tested compounds.
- Halogen-free designs: to reduce smoke and toxic gas release.
- Shielding options: aluminium/polyester tapes, tinned copper braid, or stainless steel for EMI protection.
- Conductor materials: tinned, silver-plated, or nickel-plated copper to balance conductivity and temperature tolerance.
All cables are manufactured in line with ISO 9001:2015, UL, CSA, RoHS, and REACH standards, with full batch traceability. Where higher mechanical protection is required, designs can also incorporate armour layers similar to those used in armoured cables for industrial environments. Nuclear cable buyers can be confident that every design is supported by rigorous documentation and testing.
Custom cable design and assemblies
Every nuclear installation has unique requirements. Off-the-shelf cables typically fail to meet the necessary radiation, temperature, or fire-safety performance.
CDC offers a complete custom cable service:
- Design consultation to define conductor count, size, and shielding.
- Prototype development and testing.
- Choice of insulation and jacket compounds from our extensive material library.
- Printing, identification, and colour coding.
- Bespoke cable assemblies with connectors specified by the client.
With more than 6,000 cable designs completed to date, our engineering team can quickly adapt proven solutions to your specification.
Benefits of choosing CDC
Working with Custom Designed Cables provides several advantages:
- UK manufacturing: All cables are produced in our ISO 9001:2015 certified facility.
- Sector expertise: Experience across nuclear, aerospace, defence, and medical industries.
- Material library: Access to hundreds of tested compounds with documented radiation resistance.
- Fast lead times: Typical turnaround in 7–10 days for prototypes and short production runs.
- Technical support: Free consultation and advice from our engineering team at every stage.
Nuclear cable procurement demands reliability and documented assurance. That is why we maintain open communication with clients throughout design, testing, and delivery.
Radiation resistant cable market insight
The global radiation resistant cable market is shaped by two factors: increasing investment in nuclear energy and the need for safety in high-reliability sectors. Growth is steady in the UK and EU, where operators focus on life extension of existing reactors, as well as in Asia where new facilities are being built.
CDC supplies cables for organisations across these markets by offering flexible batch sizes, documented compliance, and proven performance data. Whether you are a contractor, OEM, or procurement officer, we can provide the nuclear cables you require.
Frequently asked questions about radiation resistant cables
What makes a cable radiation resistant?
Radiation resistant cables use special polymers and insulation materials that resist degradation when exposed to ionising radiation. This allows them to maintain electrical performance and mechanical integrity over decades of service.
How long do nuclear cables last?
With correct design and installation, radiation resistant cables can last up to 40 years within a nuclear facility. Lifespan depends on exposure levels, temperature, and stress. Regular inspection and documented testing help confirm ongoing performance.
Are radiation resistant cables always halogen-free?
Most nuclear applications specify halogen-free designs to prevent toxic gas release during fire. However, material choice can vary depending on the balance of radiation tolerance, flexibility, and chemical resistance needed.
Who manufactures nuclear cables in the UK?
Custom Designed Cables is a UK-based manufacturer with ISO 9001:2015 certification and experience across more than 6,000 custom designs. Our team supports clients with free consultations, short lead times, and full compliance documentation.
Get a quote for your project
If you need radiation resistant cables for a nuclear, aerospace, or medical application, CDC can help. Send us your specification or drawing and our engineers will advise on the right materials and design.
