Custom Cable Extrusion

Leading UK Specialists in Custom Cable Extrusion

Cable extrusion — also known as cable jacketing, cable sheathing or cable oversheathing — is an essential part of the cable manufacturing process. It protects cables from mechanical damage, moisture, and chemical exposure, while also improving flexibility, performance, and longevity.

At Custom Designed Cables (CDC), we deliver bespoke cable extrusion services using advanced machinery and premium materials. Every cable we produce is engineered to meet exact operational requirements, ensuring consistent quality and reliability across all production runs.

Custom extrusion for every need

Our custom cable extrusion capabilities allow us to work with a wide range of polymers, each selected for its unique performance characteristics and operating environment. Typical considerations include:

Temperature range and flexibility
Resistance to oils, chemicals, and water
Low smoke and halogen-free properties (LSOH/LSZH)
Fire resistance and mechanical durability

We provide cable extrusion for projects of any size, from small bespoke orders to large production runs, with short lead times and consistent quality assurance.

Our cable extrusion services

Every stage of the process is managed by skilled technicians using advanced extrusion lines and precision control systems.

Our key services include:

Full extrusion capability for cables up to 40mm in overall diameter
Standard lead times of 7–10 days from enquiry to completion
Extensive range of stock extrusion materials including PP, PE, PVC, PUR/TPU,
Hytrel/TPE, TPV, LSOH/LSZH, Nylon PA12, PA11, XLPE, and XLPO
Exact colour matching or selection from a wide range of masterbatch colours
Extrusion of existing cables to alter diameter, material, or mechanical properties
Wire insulation, bedding layers, and final oversheathing options

Types of cable extrusion

Wire insulation

Wire insulation prevents electrical current from straying between conductors. It ensures safe performance and longevity, even in the most demanding environments. The materials used are specifically chosen to be suitable for the required voltage rating, flexibility, and environmental conditions of the working environment.

Bedding layers

A bedding layer improves cable shape and provides mechanical support. It can also act as a barrier against moisture and abrasion. In armoured cable construction, a bedding layer is applied before the steel wire armour to safeguard internal components.

Final cable extrusion

The outer sheath of the cable acts as the final protective layer. It holds the cable together, provides defence against external damage, and enhances mechanical strength. The materials for this are chosen according to operating temperature, exposure to chemicals, and flexibility needs. Cable printing enables outer jackets to be printed with custom branding, part numbers, or safety information, which can be a great branding and ensuring safety.

Why choose CDC for cable extrusion?

With more than 20 years of experience in cable manufacturing, CDC is trusted across industries for precision, flexibility, and quality assurance. We combine technical expertise with fast turnaround times and open communication throughout every project.

Our commitment to quality

At CDC, we are a leading UK cable manufacturer with global capability. In addition to exceptionally fast turnaround times and high-quality cable construction, we are:

UL & CSA certified for selected products
Certified to ISO 9001:2015 standards
Compliant with all relevant national and international cable standards
Backed by a comprehensive materials library and expert in-house advice

Get in touch with CDC

Our technical team will help identify the right materials and construction methods to achieve your desired performance, durability, and compliance. Contact CDC today to discuss your custom cable extrusion requirements.