Electrical Cable Manufacturing Capabilities

Key Features of our Electrical Cable Manufacturing Capabilities.

Key Feature	Minimum	Typical	Maximum
Number of Conductors	Single	2 – 105	3000+
Conductor Size	30AWG (.05mm2)	(1-28) AWG (33.6-.08mm2)	6000 MCM 6000 KCMIL
Conductor Insulation Thickness (.010 = 10 Mils)	.005 (.13mm)	.010 – .032 (.25 – .81mm)	.125 (3.18mm)
Jacket/Sheath Insulation Thickness (.010 = 10 Mils)	.005 (.13mm)	.032 – .150 (.81 – 3.81mm)	.250 (6.35mm)
Finished Cable Diameter (.010 = 10 Mils)	.100 (2.54mm)	.250 – 1.500 (6.35 – 38.1mm)	6.00 (152.4mm)

 

WIRE & CABLE STRANDING CLASS USES

Concentric-lay Conductors

• Class B: Power Cables.
• Class C: Power Cables where more flexible stranding than Class B is desired.
• Class D: Power Cables where extra flexible stranding is desired.

Rope-lay and Bunch-stranded Conductors

Class G and H shall have concentric-lay-stranded members and Class I, K, and M shall have bunched-stranded members.

• Class G: All cables for portable use.
• Class H: All cables where extreme flexibility is required, such as for use on take-up reels, etc.
• Class I: Apparatus cable and motor leads.
• Class K: Cords and cables composed of No. 30 AWG copper wires. Stationary service.
• Class M: Cords and cables composed of No.34 AWG copper wires. Constant service.

1XTech “Create” Custom Cable Manufacturing YouTube Video (16 seconds)

Typical Electrical Cable Manufacturing Time?  FAST. 

“Because You Require Quality, Quickly! ®” is our slogan for a reason. We pride ourselves on being nimble. When your electrical cable delivery truly matters most you can count on 1X Technologies to produce your cable with the fastest turnaround time anywhere relying on the best supply chain in the industry to make it happen. As your chosen wire & cable supplier we will work hard to make sure you get your cable quickly, from the factory floor to your job site as fast as we can. The lead times below are estimates and are dependent upon our supply chain of materials manufacturers but this is a good estimate, as always there can be a give or take with estimates. For a detailed quote contact your 1XTech salesman.

• Typical 600V electrical cable Production time:  2 to 4 Weeks ARO   (ARO = After Receipt of Order).
• Typical 300V electrical or electronic cable Production time: 2 to 4 weeks ARO
• 1KV – 2KV  typical electrical cable Production time: 2  to 4 weeks ARO
• 5KV – 35KV typical electrical cable Production time: 7 to 8 weeks ARO
• 46KV – 550KV typical electrical cable Production time: 10 to 12  weeks ARO
  
  
  

Expedited Electrical Cable Manufacturing Speed

While our normal electrical cable manufacturing speed is the fastest in the industry, we also offer you expedited electrical cable manufacturing services. We have manufactured and shipped 300V electrical cables within just 1 to 2 days, and 600 Volt cables within 5 to 7 days ARO from our first-in-class supply chain.

To expedite an order typically means the electrical cable manufacturing production team will need to expedite materials such as our copper rod, plastics, and chemicals used in the electrical cable manufacturing process.

They are expedited into our electrical cable factory either by hotshot delivery or by air freight. Then the electrical cable manufacturing crew usually works around the clock in order to produce your cable at lightning speed.  

Expedited Electrical Cable Manufacturing Cost vs. Benefit

Because of all the work that goes into expediting our already super-fast electrical cable manufacturing process, it can be costly. However, while the price of the electrical cable product may give some sticker shock at first when having your specialty cable on-site in just days saves your project many thousands of dollars, or in Mike from Nasa’s case, millions of dollars. The added cost of the electrical cable turns out to be just a small exchange for the tremendous added value you receive.

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Belden Cable Equivalent Manufacturers

1X Technologies Cable Company manufactures over 5000 top-of-the-line Belden Cable Equivalents, exclusively made in the USA. Your American-made, award-winning cables are cross-referenced directly from the Belden-Catalog to help you save time and money. You can buy alternatives to nearly every Belden part-number.

 

Electrical Cable Manufacturing Capabilities – Cable Reels and Wire Packaging.

1X Technologies Cable Company’s electrical cable packaging capabilities are vast. Ask us if you need something different than what you see below, we will check with our first-class network of vendors to see what we can make happen for you. 

ELECTRICAL CABLE REEL TYPES

1. Plywood Reels
2. Wood Reels
3. Steel Reels
4. Polyfiber Reels
5. Plastic Reels
6. Reel in a Box
7. Heat Treated Wood Reels
8. Heat Treated Wood Pallets
9. Cable Drums

ELECTRICAL CABLE REEL COVERINGS/PROTECTION

1. Cardboard
2. Clear Stretch Wrap
3. Printed Plastic Wrap
4. Wood Lagging
5. Recycled Fiber Board

ELECTRICAL CABLE REEL IDENTIFICATION

1. Descriptive Labels
2. Barcode Labeling
3. Tags
4. Print or Marks on Reels
5. Stickers

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Unlimited Electrical Cable Configuration Manufacturing Capabilities.

• High-Temperature Cable
• Extra Large AWG sizes, up to 6000 MCM / 6000 KCMIL
• Multiconductor Cables
• Multipair Cables
• Microminiature Cables
• Coaxial Cables
• Micro coaxial Cables
• Hybrid Cables
• Composite Cables
• Power Cables
• Lead Wire
• Flat, round braids
• Retractable coil cords

 

Custom Cable Manufacturers, Made in the USA

1X Technologies Cable Company manufactures and supplies countless types of custom cable. Precisely, custom electrical cable, custom electronic cable, and countless types of wire and cable in every color you can imagine. We make the cable and wire that makes the world go round. 

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Electrical Cable Manufacturing Capabilities Specifications

• Shielding
  Application: Overall and individual conductors/pairs
  Types: Foil, braid, spiral, Foil + braid
• Flexing
  Flex types: Rolling, bending, torsional, continuous
  Flex cycles: Over 20 million
• Ratings
  Temperature: -100 to + 450 C
  Electrical: 30, 150, 300, 600, 1000V through 550KV
• NRTL Approvals
  UL, ETL, FM, CSA, CE, HAR, RoHS, USP Class VI, IEC
• Mechanical/Environmental Manufacturing Capabilities – resistance to abrasion, oils, sunlight, chemicals, sterilization (autoclave, ETO, gamma, and more), and UV. Low outgassing.

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Electrical Cable Manufacturing Capabilities, Cable Material Types

Electrical Wire & Cable Conductor Materials

• Bare Copper (BC, SBC)
• Topcoat (TCT)
• Overcoat (OVCT)
• Oxygen-Free High Cond. (OFHC)
• Tinned Copper Weld (TCW)
• Bare Copper Weld (BCW)Tinned Copper (TC, TPC)
• IW Prebond® (PB, PBC)
• Tinned Cadmium Bronze (TCB)
• Nickel Cadmium Copper (NCC, NCa)
• Zinc-Coated Steel (ZCW)
• Silver Plated Copper (SPC)
• Percon (High Strength Copper Alloy)

Electrical Wire & Cable Insulation and Jacket Compounds

• Polyvinyl Chloride PVC
• Semi-Rigid Polyvinyl Chloride SR-PVC
• Polyethylene LDPE, HDPE, HMPE
• Polypropylene PP
• Hytrel® (Dupont) TPE
• Thermoplastic Elastomer TPE
• Thermoplastic Rubber TPRFlame Retardant PE FRPE
• Foam Polyethylene FPE
• Thermoplastic Vulcanizate
• Santoprene® (ExxonMobile) TPR / TPV
• Semi-Conductive SC-PE
• Semi-Conductive SC-PVC
• Cross-Linked Polyethylene XLPE
• Fluorinated Ethylene Propylene FEP
• FEP Teflon® (Dupont)
• Ethylene Tetrafluoroethylene ETFE Tefzel® (Dupont)

Additional Specialized Electrical Wire Insulation’s

• Irradiated Cross-Linked PVC
• Irradiated Cross-Linked PE
• Silicon Rubber
• Poly Tetrafluoroethylene PTFETapes, Tape Shields, Binders, and WrapsMylar (Polyester)
• Mylar Backed Aluminum Foil
• Foil Free Edge Mylar Backed Aluminum Foil
• Aluminum/Mylar/Aluminum
• Foam Polypropylene
• Spunbond Non-Woven Synthetics
• Non-Woven Fleece Wraps
• Copper Tape
• Mylar Backed Copper
• Tinned Copper TapePaper Separator Tapes
• Tissue Separator Tapes
• Teflon® Tapes
• Water Blocking Tapes (Dry)
• Nylon Binders
• Cotton Tapes and Binders
• Monel Mesh (Parker/Chomerics)
• Stainless Steel TapeFiller MaterialsFibrillated Poly
• Flame Retardant Fibrillated Poly
• Solid Poly Rod
• Flexible Solid Plastic Rod
• NylonSynthetic Rope
• Twisted Jute
• Hot Melt Water Block
• Fibrous Water Block (Dry)
• Cotton
• Kevlar® (Dupont)
• Insulated Kevlar® (Dupont)
• Waxed Kevlar® (Dupont)
• Hot Melt Water Blocking Compound

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Custom Electrical Cable Manufacturing Capabilities

How Custom Cable is made at 1X Technologies Cable Company.

 

Custom Electrical Cable, built fast.

1X Technologies excels at manufacturing custom cables. We can build composites, special conductor sizes, special insulation, with everything but the kitchen sink included with materials and supplies from a vast array of well-known vendors.

The 1X Technologies Custom Cable Advantage:

Advantages of working with the best custom cable manufacturers include being able to:

1. Determine physical and electrical tolerances.
2. Define the components that best fit your application like insulation, shield, jacket, etc.
3. Combine various functions, such as power, signal, coax, shielded subassemblies, and optical fiber into one cable.
4. Optimize the conductor count, stranding, size, and color-code.
5. Save money by specifying the exact quantity & lengths required. We build short runs as low 
6. Build brand recognition by printing your company’s logo and information on the jacket.

Electrical Cable Manufacturing Capabilities – Typical ICEA Color Codes

K1 COLOR CODE

For Multi-Conductor Cables(Per ICEA Insulated Cable Engineers Association and NEC National Electric Code)

#	Base	Stripe1	Stripe2
1	BLK
2	WHT
3	RED
4	GRN
5	ORG
6	BLU
7	WHT	BLK
8	RED	BLK
9	GRN	BLK
10	ORG	BLK
11	BLU	BLK
12	BLK	WHT
13	RED	WHT
14	GRN	WHT
15	BLU	WHT
16	BLK	RED
17	WHT	RED
18	ORG	RED
19	BLU	RED
20	RED	GRN
21	ORG	GRN
22	BLK	WHT	RED
23	WHT	BLK	RED
24	RED	BLK	WHT
25	GRN	BLK	WHT
26	ORG	BLK	WHT
27	BLU	BLK	WHT
28	BLK	RED	GRN
29	WHT	RED	GRN
30	RED	BLK	GRN

#	Base	Stripe1	Stripe2
31	GRN	BLK	ORG
32	ORG	BLK	GRN
33	BLU	WHT	ORG
34	BLK	WHT	ORG
35	WHT	RED	ORG
36	ORG	WHT	BLU
37	WHT	RED	BLU
38	BLK	WHT	GRN
39	WHT	BLK	GRN
40	RED	WHT	GRN
41	GRN	WHT	BLU
42	ORG	RED	GRN
43	BLU	RED	GRN
44	BLK	WHT	BLU
45	WHT	BLK	BLU
46	RED	WHT	BLU
47	GRN	ORG	RED
48	ORG	RED	BLU
49	BLU	RED	ORG
50	BLK	ORG	RED
51	WHT	BLK	ORG
52	RED	ORG	BLK
53	GRN	RED	BLU
54	ORG	BLK	BLU
55	BLU	BLK	ORG
56	BLK	ORG	GRN
57	WHT	ORG	GRN
58	RED	ORG	GRN
59	GRN	BLK	BLU
60	ORG	GRN	BLU

K2 COLOR CODE

For Multi-Conductor Cables(Per ICEA Insulated Cable Engineers Association and NEC National Electric Code)

#	Base	Stripe1
1	BLK
2	RED
3	BLU
4	ORG
5	YEL
6	BRN
7	RED	BLK
8	BLU	BLK
9	ORG	BLK
10	YEL	BLK
11	BRN	BLK
12	BLK	RED

#	Base	Stripe1
13	BLU	RED
14	ORG	RED
15	YEL	RED
16	BRN	RED
17	BLK	BLU
18	RED	BLU
19	ORG	BLU
20	YEL	BLU
21	BRN	BLU
22	BLK	ORG
23	RED	ORG
24	BLU	ORG

-#	Base	Stripe1
25	YEL	ORG
26	BRN	ORG
27	BLK	YEL
28	RED	YEL
29	BLU	YEL
30	ORG	YEL
31	BRN	YEL
32	BLK	BRN
33	RED	BRN
34	BLU	BRN
35	ORG	BRN
36	YEL	BRN

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NRTL International Markings for your Manufactured Electrical Cable

You have many choices for your electrical cable testing agency. Because we sell wire & cable that is produced and tested by a lot of different companies’ and under a lot of different standards here is a list of most of them for your reference.

(UL) – Underwriters Laboratories.

(RU) Underwriters Laboratories – Appliance Wiring Material.

(cUL)– Underwriters Laboratories (Canada). Accepted in all Seven Provinces.

(IEEE) – Institute of Electrical and Electronics Engineers.

(NEC) – National Electric Code.

(IEEE) – Institute of Electrical and Electronics Engineers Logo.

(CSA) – Canadian Standards Association.

(ETL) – ETL SEMKO.

(CEBEC) – Belgium Electrotechnical Committee.

(CEE) – International Commission for Rules for the Approval of Electrical Equipment.

(HAR) – Symbol for CENELEC.

(CENELEC) – European Committee for Electrotechnical Standardization.

(DEMKO) – Danish Electrical Testing Station (Denmark).

(ETSA) – Electricity Trust of South Australia.

(IEC) – International Electrotechnical Commission.

(IMQ) – Italian Institute of the Mark of Quality.

(K) – KEMA (Netherlands).

(NEMKO) – Norwegian Board for Testing and Approval of Electrical Equipment.

(OVE) – Austrian Association for Electrical Technology.

(SEMKO) – Swedish Institute for Testing and Approval of Electrical Equipment.

(NEC) – National Electric Code.

(VDE) – Association of German Electrical Engineers.

(SATIN) – Electrical Inspectorate (Finland).

 

Typical UL Standards for Wire & Cable Manufacturing

UL 4 Armored Cable
UL 44 Rubber Insulated Wires and Cables
UL 62 Flexible Cord and Fixture Wire
UL 83 Thermoplastic Insulated Wires and Cables
UL 133 Wires and Cables w/Varnished Cloth Insulation
UL 493 Thermoplastic Insulated Underground Feeder and Branch Circuit Cables
UL 719 Nonmetallic Sheathed Cables
UL 814 Glass Tube, Sign and Ignition Cables
UL 817 Cord Sets and Power Supply Cords
UL 854 Service Entrance Cables
UL 1063 Machine Tool Wires and Cables
UL 1072 Medium Voltage Power Cables
UL 1277 Electrical Power and Control Tray Cables with Optional Fiber Members
UL 1426 Electric Cable for Boats
UL 1569 Metal Clad Cables
UL 1581 Reference Standard for Electrical Wires, Cables, and Flexible Cords

Electrical Wire & Cable Testing Capabilities

1X Technologies Cable Company performs many extensive testing capabilities to ensure that your products meet or exceed the unique requirements for our customers’ applications. Specifically, from eye diagram requirements for special signal applications to cold bend flexibility requirements measured by utilizing a liquid nitrogen chamber. Furthermore, we will gladly work with you to establish methods for testing and reporting of results according to your specific requirements.  Most importantly, we assist you with your validation programs and first article testing.

As you can see above, we carry a variety of agency approvals from certifying bodies such as UL, CSA, ETL, CE, and VDE.

Please contact us for additional information or to discuss your specific requirements.