Whether your application requires a power cable, lead wire, or a flexible interconnect, NEWT has you covered. Material offers and design make all the difference. If high flexibility is the goal, or a targeted operating temperature, or you need a specific UL style, NEWT can tailor power leads and flexible interconnects to ensure peak performance.
- Custom Flexible Interconnects – engineered for static or dynamic bending and demanding electrical / mechanical performance
- General Purpose Power Leads – designed for power transmission, internal wiring, and UL agency approvals
| Feature | Custom Flexible Interconnects | General Purpose Power Leads |
|---|---|---|
| Engineering Level | Highly customized | UL standardized |
| Flex Life | Continuous dynamic flex | Moderate to high flex |
| Miniaturization | Extensive offerings | Limited to defined contructions |
| Voltage Rating | Application driven | Defined UL ratings |
| Industries | Robotics, aerospace, medical | Industrial, control panels, appliance |
It all starts with material selection:
Conductors
Copper is standard for conductivity, with alternatives selected by application:
- Oxygen-Free Copper – Improved oxidation resistance
- Aluminum – High conductivity-to-weight ratio
- Copper Alloys – Increased strength for repeated flexing
- Copper-Clad Steel – High-frequency + added mechanical strength
- Copper-Clad Aluminum – Lightweight, cost-effective power alternative
- Resistance Wire – Controlled resistance applications
- Magnet (Litz) Wire – Reduced AC losses at high frequency
Plating Options
Selected for temperature, corrosion resistance, and termination performance:
- Tin – Economical, solderable
- Silver – Superior conductivity & solderability
- Nickel – Up to 450°C
- Gold-Plated, Nickel-Flashed – Low contact resistance
- Platinum – Exceptional chemical resistance
- Tinned Lead – Military-grade solderability
Insulated Power Cable Materials
Selected for flex life, chemical resistance, voltage, and temperature:
- PVC – Durable, economical, flame-retardant
- TPE – Flexible PVC alternative
- Polyurethane – Superior abrasion resistance
- Silicone Rubber – High-temp, highly flexible
Performance Characteristics
Stranding & Size
- Fine stranding from 30–52 AWG (custom constructions available)
- Finished sizes from 44 AWG to 500 MCM
- Designs optimized to target: gauge, CMA/mm², conductor diameter, insulation diameter, or resistance
| Type | Strand Size | Best For |
|---|---|---|
| Flexible | 30-36 AWG | General flex |
| Extra Flexible | 38-44 AWG | Repeated motion |
| Ultra Flexible | 46-52 AWG | Tight radius applications |
Temperature Capability
| Category | Material | Temperature Capability |
|---|---|---|
| High Temperature | Silver-Plated Copper | Up to 200⁰C |
| Nickel-Plated Copper | Up to 450⁰C | |
| FEP | Up to 200⁰C | |
| PFA | Up to 250⁰C | |
| Silicone Rubber | Up to 200⁰C | |
| Low Temperature/Cryogenic | Fluoropolymers | Cryogenic capable |
| Silicone Rubber | Cryogenic capable | |
| Polyurethane | Down to -50⁰C |
Additional Design Considerations
- Chemical Resistance – Fluoropolymers, Polyester, Nylon
- High Voltage – Fluoropolymers (excellent dielectric), Silicone (corona resistant)
- Low Capacitance – Fluoropolymers (2.03-2.08), Polyethylene (2.28-2.32)
- High Flexibility – Silicone, TPE, PVC (application dependent)
