Electrical cables are used in almost every industry, from powering homes and offices to supporting industrial machinery, telecommunications and renewable energy systems. But many people still ask: what are wires made of, what are cables, and what metal is used for electrical wires?
At Custom Designed Cables, we manufacture bespoke cable solutions for a wide range of applications. Every cable is engineered using carefully selected materials to ensure reliable performance, safety and durability in its intended environment.
In this guide, we’ll explain the key components of electrical cables, the materials commonly used in cable construction, and how those materials affect cable performance.
What Are Electrical Cables?
Electrical cables are assemblies of one or more conductors used to transmit electrical power, signals or data between devices and systems. Depending on the application, cables may include insulation, shielding and protective outer jackets to improve safety, durability and signal integrity.
Modern cable design varies significantly depending on the environment and intended use, from domestic wiring and industrial automation to high-frequency data transmission and harsh-environment applications.
Main Components of an Electrical Cable
Most electrical cables are made up of four key components:
- Conductors – carry electrical current or signals
- Insulation – prevents electrical leakage and short circuits
- Shielding – protects against electromagnetic interference (EMI)
- Cable jackets – provide environmental and mechanical protection
Each material is selected based on conductivity, flexibility, heat resistance and environmental performance.
What Metal Is Used for Electrical Wires?
Copper
Copper is the most common conductor material used in electrical wires due to its excellent conductivity, flexibility and corrosion resistance. It is widely used in power cables, control cables and data cables.
Aluminium
Aluminium is lighter and more cost-effective than copper, making it popular for power transmission and large-scale infrastructure projects.
Silver & Gold
Silver offers extremely high conductivity and is used in specialist aerospace, military and high-frequency applications. Gold is typically used in connectors and precision electronic components because of its resistance to oxidation.
Tinned & Nickel-Plated Copper
Tinned copper improves corrosion resistance in marine and outdoor environments, while nickel-plated copper is designed for high-temperature applications.
Common Cable Insulation Materials
Cable insulation has many benefits. It protects conductors from environmental damage and electrical faults. Common insulation materials include:
- PVC – flexible, cost-effective and widely used
- XLPE – excellent heat and electrical resistance
- PUR – highly durable and abrasion-resistant
- Silicone rubber – ideal for extreme temperatures
- PE – commonly used in telecommunications cables
- PTFE & FEP – specialist fluoropolymers for high-performance environments
The insulation material used has a direct impact on safety, flexibility and operating lifespan.
Cable Shielding Materials
Cable shielding protects against electromagnetic and radio frequency interference. Common shielding materials include:
- Aluminium foil shielding
- Copper braid shielding
- Tinned copper braid
- Combination foil and braid shields
- Conductive polymers for lightweight specialist applications
Shielding is particularly important in instrumentation, control and data cables where signal quality is critical.
Cable Jacket Materials
A cable jacket (or cable sheathing) protects the internal components from abrasion, chemicals, moisture and UV exposure. Common jacket materials include:
- PVC – durable and economical
- PE – excellent for outdoor use
- PUR – resistant to oils and abrasion
- LSZH – low smoke, zero halogen for fire-sensitive environments
- Fluoropolymers – used in extreme heat and chemical exposure
Selecting the correct jacket material is essential for long-term cable performance and compliance.
How Cable Materials Affect Performance and Safety
The materials used in cable manufacturing directly affect:
- Electrical conductivity and efficiency
- Signal integrity
- Flexibility and durability
- Heat and chemical resistance
- Fire safety and compliance
- Environmental performance
For example, copper conductors improve energy efficiency, while LSZH materials enhance fire safety in public buildings and transport systems.
As cable technology continues to evolve alongside automation, renewable energy and high-speed communications, material selection has become increasingly important in modern cable design.
Why Choose Custom Designed Cables?
At Custom Designed Cables, we combine technical expertise with fast, reliable manufacturing to deliver bespoke cable solutions tailored to your requirements.
We offer:
- Custom cable design and manufacturing
- ISO 9001:2015 quality management
- UL & CSA approved options
- Fast turnaround times
- Technical consultation and support
Whether you need advice on what wires are made of or support with a bespoke cable project, our experienced team can help.
Frequently Asked Questions
What are wires made of?
Most electrical wires are made from conductive metals such as copper or aluminium, combined with insulation materials like PVC or XLPE.
What metal is used for electrical wires most often?
Copper is the most widely used metal for electrical wires because it offers excellent conductivity, durability and flexibility.
What are cables used for?
Electrical cables are used to transmit electrical power, signals and data across residential, commercial and industrial applications.
Looking for expert advice on cable materials or bespoke cable manufacturing? Contact our helpful team at Custom Designed Cables today for expert advice.