In our increasingly connected world, the demand for reliable and efficient cables is higher than ever. Whether it’s for electrical power distribution or telecommunications, cables are the unsung heroes that keep our homes, businesses, and cities running smoothly. But have you ever wondered how these vital components are made?
Cable manufacturing, or cable construction, is a comprehensive process that encompasses everything from initial design and material selection to the final steps of testing and distribution.
Whether you require braided cables for protection against electromagnetic interference, or multicore cables for transmitting multiple signals, dive into the world of cable manufacturing and discover the fascinating journey from raw materials to the essential products that power our daily lives.
What is cable manufacturing?
Cable manufacturing is simply the production of electrical power or telecommunication signal cables – regardless of whether they’re custom cables or mass-produced. Cable manufacturing describes the overall production process, from cable design and planning, all the way to packaging and distribution.
The cable manufacturing process
So you may be wondering, ‘How are cables manufactured?’. The cable manufacturing process has 11 distinct steps to it, with all but 2 necessary for the production of custom and mass-produced electrical and telecommunications cables. These steps are:
Step 1: Design and planning
The first step in the cable manufacturing process is the initial design and planning.
Here, cable manufacturers and specialist engineers work together to determine the specifications needed for the cable, based on its intended use (or the client’s individual needs). This includes voltage rating, environmental conditions, and mechanical properties.
Then, detailed blueprints and design plans are created – outlining the specific materials, dimensions, and construction methods needed to manufacture the cable.
Step 2: Material selection
Once the design and planning stage is complete, the cable manufacturers then need to select the materials needed for the cable.
There are three types of materials needed for cable manufacturing:
- Conductors: A metal (usually copper or aluminium) for the main component of the cable, used for electrical conductivity.
- Insulation materials: A synthetic material (like PVC, XLPE, or rubber), used for its thermal and electrical properties inside the cable.
- Sheathing materials: More synthetic material to cover the outside of the cable, chosen for durability and environmental resistance.
Step 3: Conductor formation
The third step in the cable manufacturing process is forming the conductive material.
Firstly, large metal rods are drawn through dies to create thin wires – known as wire drawing. This reduces the diameter of the conductor material whilst increasing its length and improving the wire’s overall tensile strength.
Then, the drawn wire is heated to relieve any internal stresses, known as annealing. This makes the wire more ductile and conductive.
Step 4: Stranding
After the conductor wires are formed, they are then stranded together.
Known as bunching, individual wires are twisted together to form a strand. This process enhances the wire’s flexibility and mechanical strength. The strands are then compacted, which works to reduce the overall diameter of the wire and further improve its conductivity.
Step 5: Insulation
The fifth step in this cable manufacturing process is wire insulation.
Here, the insulation material is extruded onto the conductor, by heating up the material and uniformly applying it around the wire. The insulated wire is then cooled quickly, allowing the material to solidify around the wire.
Step 6: Cabling
Now it is the stage in the process to form the cable.
Firstly, multiple insulated conductors are twisted together to form a cable. Here, the twisting pattern will depend on the type of cable being manufactured, and what it will be used for.
After that, the spaces between the conductors are filled with non-conductive materials, helping maintain the shape of, and adding additional strength to, the overall cable.
Step 7: Shielding (if applicable)
The seventh step in this process is optional, depending on the type of cable being manufactured and how it will be used. This step is known as shielding.
In this step, the cable can be shielded using metal braids, tapes, or foils, to help protect it against electromagnetic interferences (known as EMI). The shielding material is applied over the cable core – usually in conjunction with an additional insulating layer.
Step 8: Sheathing
Moving onto the next necessary step; cable sheathing, or also known as cable extrusion and cable jacketing.
Here, an outer sheath is extruded onto the cable, by heating up the material and applying it over the cable, before allowing it to cool quickly. This outer sheath provides mechanical protection and environmental resistance to the cable – making it more durable and fit for its intended purpose.
Then the cable is marked with identification information, including; the manufacturer, the cable’s specifications, and its length markers.
Step 9: Armouring (if applicable)
Armouring is another step that isn’t always applicable in the cable manufacturing process.
For cables that require additional protection, metal tapes or wires can be applied over the outer sheath. Then, another sheath layer is applied over the armour, to protect it from corrosion or mechanical damage.
Step 10: Testing and quality control
The tenth step in the cable manufacturing process, considered one of the most important steps, is testing and quality control.
All manufactured cables will go through rigorous testing during this step, including:
- Electrical testing: Ensuring that the cable meets electrical specifications, including resistance, capacitance, and insulation integrity.
- Mechanical testing: Testing the cable for tensile strength, flexibility, and durability.
- Environmental testing: Assessing the cable’s performance under various environmental conditions – like temperature, moisture, and UV exposure
Any cables that fail these tests will not be fit for purpose and will have to be discarded.
Step 11: Packaging and distribution
The final step in the cable manufacturing process is packaging and distribution.
All manufactured cables are cut to length,k and then coiled or wound onto reels. These cables are then packaged securely, to protect them from damage during transit, with protective layers and labels. After this, the cables are then distributed to customers, ensuring safe handling and delivery.
Benefits of cable manufacturing
Cable manufacturing has a whole host of benefits – some of which may surprise you, considering this is an industry many fail to even think exists. These benefits include:
1. Economic impact
The cable manufacturing industry has a wide economic impact.
Not only does the cable manufacturing industry provide numerous employment opportunities, from engineering and production to sales and logistics, but it also supports the economic growth of other sectors that rely on cable manufacturing. These sectors include; energy, telecommunications, and transportation (to name a few).
2. Technological advancement
Cable manufacturing is often found to be at the forefront of technological advancement.
The industry drives innovation in materials, science, engineering, and production technologies – leading the development of more efficient, durable, and versatile cables across a wide range of other sectors. This innovation then supports other emerging technologies, such as 5G, electric vehicles, renewable energy systems, and smart grids.
3. Infrastructure development
The cable manufacturing industry also supports infrastructure development.
Manufactured cables provide power distribution, generation, and transmission to residential, commercial, and industrial users across the country – ensuring a constant stable and efficient supply of electricity.
They also support the telecommunication services these users depend on, through the production of fibre optic and other communication cables. This enables high-speed internet, telephone services, and data transmission – facilitating global connectivity that no other industry could provide.
4. Safety and reliability
The high standards set by the cable manufacturing industry provide safety and reliability.
The rigorous testing and quality control that goes into the cable manufacturing process ensures that all cables meet stringent safety standards – reducing the risk of electrical fires, malfunctions, and other hazards. This also allows the cables to be more durable and resistant to environmental stressors, such as temperature extremes, moisture, and mechanical wear.
5. Environmental benefits
Did you know that the cable manufacturing industry also has environmental benefits?
The industry is increasingly adopting sustainable practices, such as recycling materials and using eco-friendly production methods, to reduce its environmental footprint. But on a larger scale, the development of high-efficiency cables in the cable manufacturing industry reduces energy losses during transmission; contributing to global energy conservation efforts.
6. Versatility and customisation
The cable manufacturing industry provides a wide variety of versatility and customisation for its clients and users.
Cable manufacturing produces a variety of cables, tailored to so many different applications and sectors, from household wiring and industrial power systems to specialised uses like underwater cabling and aerospace wiring.
However, with the development of custom cables, manufacturers can create customised solutions to meet extremely specific requirements from their clients – ensuring optimal performance in diverse environments and applications.
7. Enhancing global trade
With the cable manufacturing industry’s wide economic impact also comes the enhancement of global trade.
Cable manufacturers have increasingly more export opportunities, by producing high-quality cables domestically and exporting them around the world – enhancing trade relationships and contributing to the wider global economy. By remaining compliant with international standards, cable manufacturers can participate in global markets, whilst also ensuring compatibility across various regions.
8. Supporting critical industries
Did you know that the cable manufacturing industry supports critical industries, too?
Healthcare is one of the biggest industries that need custom cables. Reliable, durable and environmentally resistant cables are vital in medical equipment, ensuring the safe and efficient use of live-saving devices in all medical settings, globally.
Furthermore, cables are also essential to transportation, including the automotive, aerospace and railway industries. Manufactured cables support not only the functionality but also the safety of vehicles and infrastructure across the world.
Challenges of cable manufacturing
However, to have such a wide range of benefits, there are challenges to the cable manufacturing industry. These include things such as:
1. Quality control and standards compliance
Quality control and standards compliance are often a struggle in the cable manufacturing industry.
During the cable manufacturing process, it can often be difficult to meet stringent international standards. This requires rigorous quality control measures that take a lot of time, money, and often result in a lot of wasted cables. Ensuring this consistency in product quality, especially in the large volumes produced in mass-produced cable manufacturing, makes this process even more challenging.
2. Material sourcing and costs
Whether the manufacturer mass-produces cables or specifically develops custom cables, material sourcing and costs are a constant challenge in the cable manufacturing industry.
Securing stable and cost-effective sources of raw materials, especially copper and aluminium, is often difficult. Along with the fluctuating prices of these raw materials, not only can it impact manufacturing costs and profitability, but it can also delay production.
3. Environmental regulations and sustainability
Whilst the cable manufacturing industry is moving towards a more sustainable future, this doesn’t mean that it isn’t a challenge.
Adhering to stringent environmental regulations, as well as individual improvements on sustainable practices, requires significant adjustments in manufacturing practices. These regulations and improvements, such as making efforts to recycle and reduce emissions, demand innovation and investment – something to which smaller manufacturers may not have access to.
4. Production efficiency and downtime
Many cable manufacturers, custom and large-scale, are challenged with production efficiency and downtime.
With so many industries depending on cables, and the growth of technological innovation and advancement, maintaining high operational efficiency and minimising downtime is critical for meeting production targets.
Not only does this mean investing in more equipment and more staff, but manufacturers are also challenged with consistently managing equipment maintenance and failures, to avoid disruptions which could tarnish the achievability of their targets.
5. Workforce training and skill development
The cable manufacturing industry requires a lot of skilled workers and regular workplace training, but this can often be difficult to find and make time for.
With the technological and engineering skills required in cable manufacturing, finding and retaining skilled workers proficient in these technologies is often a persistent challenge. Then, once you’ve hired those people, it is essential that you find the time to continuously keep them up to date with training and emerging technological advancements.
6. Supply chain management
For any business, managing supply chains can be difficult. However, supply chain management is a constant challenge in the cable manufacturing industry.
The cable manufacturing industry has a complex supply chain, with multiple suppliers and logistic partners. Mitigating risks from supply chain disruptions, such as natural disasters, geopolitical issues, and raw material shortages is a constant challenge – let alone managing the coordination of all those involved.
To learn how cable manufacturing can benefit your cabling needs, contact our expert team today, or find more resources on our blog.
