Leading wire insulation manufacturer in the UK
Wire insulation is a critical stage in cable manufacturing, forming the foundation of a safe, reliable and high-performance cable. Also referred to as conductor insulation or core insulation, it ensures electrical current remains controlled, prevents leakage and protects conductors from environmental and mechanical stress.
At Custom Designed Cables, we are a trusted UK wire insulation manufacturer, specialising in both standard and custom cable insulation solutions. With decades of combined industry experience and advanced extrusion technology, we manufacture insulated conductors to exact specifications across a wide range of industries.
Our custom wire insulation services
We provide a fully flexible and responsive wire insulation service designed around your project requirements:
- All conductor insulation requirements are catered for, from prototypes to large-scale production (low MOQs available)
- Fast turnaround times, with typical lead times of 7–10 days from initial enquiry
- Wide range of masterbatch colours in stock, with precise colour matching available
- Capability to manufacture cables from 0 to 20mm overall diameter
- Conductor sizes from 0.09mm² (28 AWG) up to 120mm² (4/0 AWG/kcmil)
- Extensive material range including PVC, PE, PP, PUR/TPU, Hytrel/TPE, TPV, XLPE, XLPO, Nylon (PA11/PA12), LSOH/LSZH
- Production of striped conductors across multiple sizes
- Conductor printing for customer-specific identification and compliance
- Expert technical guidance on material selection and performance requirements
Using modern extrusion processes and strict quality controls, we ensure consistent insulation thickness, durability and performance across every production run.
Choosing the right wire insulation material
Selecting the correct wire insulation material is essential for ensuring long-term performance, safety and compliance. The right material will depend on:
- Operating voltage requirements
- Environmental exposure (moisture, chemicals, UV)
- Mechanical stress and flexibility needs
- Temperature range and thermal resistance
Our experienced team provides practical, application-led advice to help you select the most suitable insulation type, balancing performance, compliance and cost-effectiveness.
Electrical performance and compliance
Wire insulation material and wall thickness play a key role in determining a cable’s maximum operating voltage and overall electrical performance.
We work closely with customers to ensure all insulated conductors meet required specifications and relevant industry standards. By carefully controlling insulation thickness and material selection, we help minimise electrical interference, prevent current leakage and maintain signal integrity.
Operating temperature range
Different insulation materials offer varying levels of thermal resistance. Our manufacturing capabilities support continuous operating temperatures from -65°C to 150°C, ensuring reliable performance across both standard and extreme environments. This makes our insulated conductors suitable for industries such as:
- Automotive and transport
- Industrial machinery
- Energy and utilities
- Construction and infrastructure
- Marine and offshore
Custom cable insulation solutions
As a specialist in custom cable design and custom wire insulation, we understand that no two applications are the same. We offer fully bespoke insulation solutions, including:
- Custom material formulations
- Application-specific insulation thickness
- Colour coding and identification systems
- Performance optimisation for harsh environments
From initial consultation through to production, our team works closely with you to deliver a solution that meets your exact technical and operational requirements.
Why choose Custom Designed Cables?
We are more than just a wire insulation supplier, we are a long-term manufacturing partner. Our reputation is built on:
- Proven industry expertise in cable manufacturing and insulation
- Fast, reliable lead times to support urgent and ongoing projects
- Consistent quality assurance across all production runs
- Comprehensive material knowledge and technical support
- Customer-focused service, from enquiry to delivery
We maintain clear communication throughout every stage of your project, ensuring deadlines are met and expectations are exceeded, even on complex or time-sensitive requirements.
Contact our team today to discuss your requirements, request a quote or get expert advice on the best insulation solution for your application.
