Wire & Cable Glossary

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Abrasion Resistance

Ability of a wire, cable or material to resist surface wear.

Alloy

A metal formed by combining two or more different metals to obtain desirable properties.

Alternating Current (AC)

Electric current that continually reverses its direction. It is expressed in cycles per second (Hertz or Hz).

Ambient Temperature

The temperature of the medium surrounding an object.

Ampacity

The maximum current an insulated wire or cable can safely carry without exceeding either the insulation or jacket material limitations.

Ampere

A unit of current.

Anneal

To soften and relieve strains of metal by heating to just below melting point then slowly cooling. Annealing lowers the tensile strength of copper while improving flex life and flexibility.

ANSI

American National Standards Institute.

ASA

American Standards Association. Former name of ANSI.

ASTM

American Society for Testing and Materials.

Attenuation

Reduction of signal strength during transmission. In cables generally expressed in dB per unit length usually 1000 feet.

Auto Frequency

The range of frequencies audible to the human ear. Usually 20-20000 Hz.

AWG

American Wire Gauge.

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Band Width

The frequency range of transmitted electrical signals expressed in Hertz.

Bare Conductor

A conductor having no covering coating or cladding on the copper.

Bend Radius

Radius of curvature that a cable can bend before the risk of breakage or increased attenuation occurs. To determine bend radius a good rule of thumb is not to exceed ten times the cable diameter.

Binder

A spirally served tape or thread used to hold cable components in place.

Bond Strength

Amount of adhesion between surfaces e.g. in bonded ribbon cables.

Braid

A group of textile or metallic filaments interwoven to form a tubular flexible structure which may be applied over one or more wires or flattened to form a strap.

Braid Angle

Braid angle is the angle formed between the individual braid strands and the longitudinal axis of the cable. The braid angle affects the cable’s flexibility, shielding effectiveness, and mechanical durability, with different applications requiring different braid configurations.

Breakdown Voltage

Breakdown voltage is the minimum voltage at which an insulating material fails and allows electrical current to pass through by arcing or dielectric breakdown. It is an important measure of an insulation material’s ability to withstand electrical stress without failure.

Bunch Stranding

Bunch stranding is a method of manufacturing conductors by twisting multiple wires together without maintaining a specific geometric pattern. This construction provides greater flexibility than a solid conductor.

Bus-Bar Wire

Bus-bar wire is an uninsulated, typically tinned copper conductor used to distribute electrical current between multiple connection points. It serves as a common electrical path in switchgear, control panels, grounding systems, and power distribution equipment.

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Cable Assembly

A cable assembly is a completed cable with connectors, terminals, or other hardware attached and ready for installation.

Cabling

Cabling is the process of grouping or twisting together two or more insulated conductors to form a cable. The arrangement of the conductors helps improve flexibility, reduce electrical interference, and maintain consistent performance.

Capacitance

Capacitance is the ability of a dielectric material between conductors to store electrical energy when a voltage is applied. In cables, capacitance is typically measured in picofarads (pF) per unit length and can affect signal transmission, especially at higher frequencies.

Category Cable

A category cable is a performance classification established by the Telecommunications Industry Association (TIA) and the Electronic Industries Alliance (EIA). Categories such as Cat5e, Cat6, and Cat6A define a cable’s bandwidth, transmission speed, and electrical performance.

CEC (Canadian Electrical Code)

The Canadian Electrical Code (CEC) is the national standard governing the safe installation and maintenance of electrical equipment and wiring in Canada. It establishes requirements designed to protect people and property from electrical hazards.

Cellular Polyethylene

Cellular polyethylene is a foamed insulation material containing millions of closed air cells within a polyethylene matrix. The trapped air lowers the dielectric constant, reducing signal loss and improving the electrical performance of communication cables.

Characteristic Impedance

Characteristic impedance is the ratio of voltage to current along a transmission line when electrical energy is traveling through it. Maintaining the proper characteristic impedance minimizes signal reflections and ensures efficient signal transmission in high-frequency cables.

Cigarette Wrap

Cigarette wrap is a method of applying tape insulation longitudinally around a conductor rather than wrapping it in a spiral. This construction provides uniform insulation coverage while minimizing material overlap.

Circular Mil

The area of a circle one one-thousandth of an inch (.001″) in diameter. Used in expressing wire cross sectional area and to determine conductivity and gauge size that various combinations of conductors will produce.

Cladding

Method of applying a layer of metal over another metal whereby the junction of the two metals is continuously welded.

Co-Polymer

A co-polymer is a polymer produced by chemically combining two or more different types of monomers. Co-polymers are engineered to provide improved properties such as flexibility, chemical resistance, strength, or heat resistance compared to single-monomer polymers.

Coaxial Cable

Cable consisiting of two cylindrical conductors with a common axis separated by a dielectric.

Cold Bend

A cold chamber test to determine effects of specified temperatures on cable which has been wrapped around a mandrell.

Cold Flow

Permanent deformation of an insulation due to mechanical force or pressure.

COLDflex Ground Cable™

New England Wire’s flexible low-temperature ground cable for power distribution applications.

Color Code

A system for identifying components of cables using solid color and striped jackets.

Common Axis Cabling

Common axis cabling is a construction method in which multiple insulated conductors are twisted around a single central axis. This design produces a smaller, more uniform cable while improving flexibility and overall cable geometry.

Compacted Stranded Conductor

A compacted stranded conductor is manufactured by compressing stranded wires into a smaller overall diameter than a standard stranded conductor – typically 8-10% less than the standard nominal diameter. This process reduces air gaps between strands, resulting in a more compact cable with improved conductivity and reduced overall size.

 

Composite Cable

A composite cable combines two or more different types or sizes of conductors within a single cable jacket. These cables allow multiple electrical or communication functions, such as power and data transmission, to be carried through one cable.

Compound

A compound is an insulating or jacketing material produced by blending polymers with additives such as stabilizers, fillers, plasticizers, and flame retardants. The formulation is designed to provide specific electrical, mechanical, and environmental performance characteristics.

Concentric Stranding

Concentric stranding is a conductor construction in which layers of wires are twisted around a central wire or core in alternating directions. This design provides a round conductor with excellent flexibility, strength, and electrical performance.

Concentricity

Concentricity is the measurement of how closely the center of a conductor aligns with the geometric center of its surrounding insulation. Good concentricity ensures uniform insulation thickness, improving electrical performance and reducing the risk of insulation failure.

Conductance

Conductance is the ability of a material or conductor to allow the flow of electrical current. It is the reciprocal of electrical resistance and is measured in siemens (S).

Conductivity

Conductivity is a material’s ability to carry electrical current efficiently. It is commonly expressed as a percentage of the International Annealed Copper Standard (IACS), with pure annealed copper assigned a conductivity value of 100%.

Conductor

A conductor is a material that allows electrical current to flow with relatively low resistance. In electrical cables, the conductor serves as the primary path for transmitting electrical energy or signals.

Connector

A connector is a device used to mechanically and electrically join two or more conductors or cables. Connectors provide secure, reliable electrical connections while allowing equipment to be connected, disconnected, or replaced as needed.

Contact

A contact is the conductive component inside a connector that carries electrical current between mated connectors. Contacts are typically manufactured from highly conductive metals and are often plated to improve corrosion resistance and electrical performance.

Continuity Check

A continuity check is a test performed to verify that electrical current can flow uninterrupted through a conductor or cable. It is commonly used during manufacturing, installation, and maintenance to detect broken conductors or faulty connections.

Copper-Clad Steel

Copper-clad steel is a composite conductor consisting of a steel core permanently bonded with an outer layer of copper. This construction combines the high strength of steel with the excellent electrical conductivity and corrosion resistance of copper.

Core

A core is the central component or group of components around which additional cable elements, such as insulation, shielding, or jackets, are applied. Depending on the cable design, the core may consist of one or multiple conductors.

Corona Discharge

Corona discharge is a localized electrical discharge caused by the ionization of air surrounding a conductor subjected to a high electric field. Over time, corona can degrade insulation materials, generate electrical noise, and reduce the service life of high-voltage cables.

Corrosion

Corrosion is the gradual deterioration of a material caused by chemical reactions with its environment or by galvanic action between dissimilar metals. In electrical systems, corrosion can increase resistance, weaken connections, and reduce overall reliability.

Crazing

Crazing refers to the formation of very fine surface cracks in plastic materials due to stress, aging, or environmental exposure. Although initially cosmetic, severe crazing can reduce the mechanical strength and durability of cable insulation.

Cross-Linked

Cross-linking is a process that creates chemical bonds between polymer chains through chemical treatment or electron-beam irradiation. Cross-linked materials offer improved heat resistance, mechanical strength, chemical resistance, and dimensional stability compared to standard thermoplastics.

Crosstalk

Crosstalk is the unwanted transfer of electrical signals from one conductor or cable pair to another. Excessive crosstalk can reduce signal quality and communication performance, particularly in high-speed data transmission systems.

CSA (Canadian Standards Association)

The Canadian Standards Association (CSA) is a standards development organization that establishes safety, performance, and certification standards for products used in Canada and internationally. CSA certification indicates that a product has been tested to meet applicable safety and quality requirements.

Current

Current is the flow of electric charge through a conductor and is measured in amperes (A). It represents the rate at which electrical energy moves through a circuit.

Current Carrying Capacity

Current carrying capacity is the maximum continuous electrical current that a conductor or cable can safely carry without exceeding its allowable operating temperature. This value depends on conductor size, insulation type, ambient temperature, and installation conditions.

Cut Through

Cut through is a mechanical test that measures an insulation or jacket material’s resistance to penetration by a sharp edge or blade. The test helps evaluate the material’s durability and ability to protect the conductor from mechanical damage during installation and service.

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dB (Decibel)

A decibel (dB) is a logarithmic unit used to measure the ratio between two levels of power, voltage, or signal strength. In wire and cable applications, decibels are commonly used to express signal attenuation (loss) or amplification (gain), particularly in communication and data transmission systems.

DC (Direct Current)

Direct Current (DC) is the flow of electrical current in a single direction without periodically reversing polarity. DC power is commonly used in batteries, electronic devices, automotive systems, and renewable energy applications.

Derating Factor

A derating factor is a multiplier used to reduce the current carrying capacity (ampacity) of a wire or cable when operating under conditions different from standard ratings. Factors such as elevated ambient temperatures, bundled cables, or limited airflow may require derating to prevent overheating and ensure safe operation.

Dielectric

A dielectric is a nonconductive insulating material that separates electrical conductors while allowing an electric field to exist between them. Common dielectric materials used in cables include polyethylene, polypropylene, and fluoropolymers, which provide insulation and influence electrical performance.

Dielectric Breakdown

Dielectric breakdown occurs when an insulating material is subjected to an electric field strong enough to cause it to become electrically conductive. This failure allows current to pass through the insulation, often resulting in arcing, overheating, or permanent damage to the cable.

Dielectric Loss

Dielectric loss is the amount of electrical energy converted into heat within an insulating material when it is exposed to an alternating electric field. Lower dielectric loss improves signal efficiency and reduces energy dissipation, especially in high-frequency communication cables.

Dielectric Strength

Dielectric strength is the maximum electric field an insulating material can withstand before electrical breakdown occurs. It is typically expressed as volts per unit thickness, such as volts per mil or kilovolts per millimeter, and is an important measure of insulation performance.

Dielectric Test

A dielectric test, often called a high potential (hi-pot) test, applies a voltage greater than a cable’s normal operating voltage for a specified period to verify the integrity of its insulation. This test helps identify insulation defects that could lead to electrical failure during service.

Differential Impedence

Differential impedance is the ratio of voltage to current between two conductors carrying equal and opposite electrical signals. Maintaining the correct differential impedance is critical for high-speed data transmission because it minimizes signal reflections and preserves signal integrity.

Drain Wire

A drain wire is an uninsulated conductor placed in direct contact with a cable’s metallic shield. It provides a convenient path for grounding the shield during cable termination, helping to reduce electromagnetic interference (EMI) and simplify connector installation.

Drawing

Drawing is the manufacturing process of pulling metal through one or more precision dies to reduce its diameter to a desired size. This process improves dimensional accuracy and produces wire suitable for a wide range of electrical and electronic applications, including extremely fine conductors smaller than 50 AWG.

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Elastomer

An elastomer is a polymer material with elastic properties that allow it to stretch under stress and return to its original shape when the stress is removed. Elastomers are commonly used as cable insulation and jacketing because they provide excellent flexibility, durability, and resistance to environmental conditions.

Electromagnetic

Electromagnetic refers to the interaction of electric and magnetic fields produced by the movement of electric charges through a conductor. Electromagnetic fields are fundamental to the operation of electrical systems and can influence nearby electronic devices if not properly controlled.

Electroplating

Electroplating is the process of depositing a thin layer of one metal onto the surface of another using an electric current. In wire and cable manufacturing, electroplating is commonly used to apply coatings such as tin, silver, or nickel to improve corrosion resistance, solderability, and electrical performance.

Electrostatic

Electrostatic refers to electric charges that remain stationary rather than flowing as an electric current. Electrostatic charge buildup can lead to electrostatic discharge (ESD), which may damage sensitive electronic components if not properly controlled.

Elongation

Elongation is the amount a material can stretch before breaking, usually expressed as a percentage of its original length. In wire and cable testing, elongation is used to evaluate the flexibility, ductility, and mechanical performance of conductors and insulation materials.

EMF (Electromotive Force)

Electromotive force (EMF) is the electrical potential or voltage that drives current through a circuit. Although called a “force,” EMF is measured in volts and represents the energy supplied per unit of electric charge.

ETFE (Ethylene Tetrafluoroethylene)

Ethylene Tetrafluoroethylene (ETFE) is a high-performance fluoropolymer known for its excellent mechanical strength, chemical resistance, and wide operating temperature range. It maintains its electrical and physical properties in temperatures from approximately -200°C to 200°C, making it well suited for aerospace, military, and industrial cable applications.

ETP (Electrolytic Tough Pitch)

Electrolytic Tough Pitch (ETP) copper is a highly refined copper that contains approximately 99.9% pure copper with a small amount of oxygen. It offers excellent electrical and thermal conductivity, making it the most widely used conductor material in electrical wire and cable manufacturing.

Extrusion

Extrusion is a manufacturing process in which plastic or elastomer is forced through a die to apply a continuous layer of insulation or jacketing around a conductor or cable core. This process produces a uniform coating that provides electrical insulation, mechanical protection, and environmental resistance.

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F (Farad)

A farad (F) is the unit of measurement for electrical capacitance. One farad represents the capacitance of a device that stores one coulomb of electrical charge when one volt of potential is applied.

FEP (Fluorinated Ethylene Propylene)

Fluorinated Ethylene Propylene (FEP) is a high-performance fluoropolymer known for its excellent electrical insulation, chemical resistance, and high-temperature stability. It offers low dielectric loss, making it an ideal insulation material for high-frequency, aerospace, medical, and industrial cable applications.

Filler

A filler is a nonconductive material placed within a cable to occupy empty spaces between insulated conductors. Fillers help maintain a round cable shape while improving flexibility, mechanical strength, and overall structural stability.

Flame Resistance

Flame resistance is the ability of a material to withstand exposure to flame without continuing to burn after the ignition source has been removed. Flame resistant materials help reduce fire hazards and improve the safety of electrical cables.

Flame Retardance

Flame retardance is the ability of a material to slow, resist, or inhibit the spread of flames during combustion. Flame retardant cable materials are formulated to minimize fire propagation and reduce the risk of flame spreading along a cable.

Flammability Rating

A flammability rating is a standardized classification that measures how easily a material ignites, burns, and self-extinguishes when exposed to fire. Ratings established by organizations such as UL help determine the suitability of cable materials for specific applications and environments.

Flat Braid

A flat braid is a woven conductor or shielding material manufactured in a flattened shape to a specified width. Flat braids are commonly used for grounding, bonding, and electromagnetic shielding because they provide excellent flexibility and a large contact surface.

Flex-Life

Flex-life is a measure of a wire or cable’s ability to withstand repeated bending or flexing without mechanical or electrical failure. Good flex-life is essential for applications involving continuous movement, such as robotics, automation equipment, and portable devices.

Flexibility

Flexibility is the ease with which a wire or cable can bend without sustaining damage or significantly affecting its electrical performance. Factors such as conductor construction, insulation material, and cable design all influence flexibility.

Flouropolymers

Fluoropolymers are a family of high-performance plastics known for their excellent chemical resistance, electrical insulation, and ability to withstand extreme temperatures. Common fluoropolymers used in wire and cable manufacturing include ETFE, FEP, and PFA, which are widely used in demanding industrial, aerospace, and medical applications.

Foamed Dielectric

A foamed dielectric is an insulating material containing microscopic air-filled cells that reduce its overall dielectric constant. By incorporating air into the polymer, foamed dielectrics improve signal transmission, lower capacitance, and reduce attenuation in high-frequency cables.

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Gas Out

A gas out is the formation of small voids or air pockets within a cable’s insulation caused by gases escaping during the extrusion process. These voids can reduce the insulation’s electrical performance and mechanical integrity, making process control critical during cable manufacturing.

Gauge

Gauge is a term used to describe the physical size or diameter of a wire. In North America, wire size is typically specified using the American Wire Gauge (AWG) system, where a smaller AWG number indicates a larger conductor diameter and generally a higher current-carrying capacity.

Ground

Ground is a conductive connection between an electrical circuit and the earth, or another large conducting body, that serves as a common reference point for voltage. Proper grounding helps protect people and equipment by providing a safe path for fault current and reducing the risk of electrical shock or damage.

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H (Henry)

The henry (H) is the unit of measurement for electrical inductance. One henry is the amount of inductance that produces one volt of induced electromotive force when the current changes at a rate of one ampere per second.

Halogen

Halogens are a group of chemical elements consisting of fluorine, chlorine, bromine, iodine, and astatine. In wire and cable manufacturing, halogen-containing compounds are often added to insulation and jacketing materials to improve flame retardancy, although halogen-free alternatives are preferred in applications where low smoke and reduced toxic emissions are required.

Hard Drawn

Hard drawn wire is conductor material that has been cold-worked by drawing through dies but has not been annealed afterward. As a result, it has higher tensile strength but lower flexibility and ductility than annealed wire.

Harness

A wire harness is an organized assembly of wires, cables, connectors, and protective coverings used to transmit electrical power or signals between components. Harnesses simplify installation, improve reliability, and protect wiring from vibration, abrasion, moisture, and environmental damage.

HDPE (High Density Polyethylene)

High Density Polyethylene (HDPE) is a durable thermoplastic known for its high strength-to-density ratio, excellent chemical resistance, and low moisture absorption. It is commonly used as insulation or jacketing material for communication, power, and industrial cables.

Heat Seal

Heat sealing is a process that joins or seals thermoplastic materials by applying heat and pressure until the materials fuse together. In cable manufacturing, heat sealing is often used for protective films, packaging, and certain insulation applications.

Helical Stripe

A helical stripe is a continuous colored stripe applied in a spiral pattern around a wire or cable insulation. It provides a simple and effective method of identifying individual conductors within a cable assembly.

Hi-Pot (High Potential Test)

A High Potential Test (Hi-Pot) verifies the electrical integrity of insulation by applying a voltage significantly higher than the cable’s normal operating voltage. The test helps identify insulation defects, manufacturing flaws, or damage that could result in electrical failure.

Hook-Up Wire

Hook-up wire is a single insulated conductor used for internal wiring of electrical and electronic equipment. It is commonly used in low-voltage and low-current applications, typically rated for 600 volts or less, where flexibility and reliable insulation are required.

Hot Tin Dip

Hot tin dipping is the process of coating bare copper wire by passing it through a bath of molten tin. Although this method provides excellent corrosion resistance and solderability, it has largely been replaced by electroplating because of its greater precision and manufacturing efficiency.

Hybrid Cable

A hybrid cable combines two or more different cable types or transmission media within a single outer jacket. These cables may include combinations of power conductors, signal wires, fiber optics, coaxial cables, or fluid tubes to support multiple functions in one compact assembly.

HYflex™ Power Distribution Cables

HYflex™ Power Distribution Cables are proprietary power cables developed by New England Wire Technologies for diesel-electric and hybrid vehicle applications. They are manufactured using high-performance insulation compounds designed to withstand operating temperatures up to 125°C and voltages up to 600V AC, while providing durability in demanding transportation environments.

Hygroscopic

Hygroscopic describes a material’s ability to absorb and retain moisture from the surrounding environment. In wire and cable applications, hygroscopic materials can affect electrical performance and processing, making moisture-resistant materials preferable for many insulation and jacketing applications.

Hz (Hertz)

Hertz (Hz) is the standard unit used to measure frequency and represents one cycle per second. It is commonly used to specify the operating frequency of electrical power systems, communication signals, and electronic equipment.

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IEEE (Institute of Electrical and Electronics Engineers)

The Institute of Electrical and Electronics Engineers (IEEE) is a global professional organization that develops technical standards and promotes innovation in electrical engineering, electronics, computing, and related fields. IEEE standards are widely used throughout the wire and cable industry to ensure product compatibility, safety, and performance.

Impedance

Impedance is the total opposition a circuit presents to the flow of alternating current (AC), combining both resistance and reactance. It is measured in ohms (Ω) and is a critical electrical characteristic in communication and transmission cables as proper impedance matching minimizes signal reflections and transmission losses.

Inductance

Inductance is the property of a conductor or circuit that opposes changes in current flow by generating a magnetic field. It is measured in henrys (H) and influences the performance of AC power systems, communication cables, and electronic circuits.

Insulation

Insulation is a nonconductive material that surrounds electrical conductors to prevent unwanted current flow and protect against electrical shock and short circuits. Common insulation materials include PVC, polyethylene, fluoropolymers, and rubber compounds, each selected based on the application’s electrical, mechanical, and environmental requirements.

Interference

Interference is any unwanted electrical or electromagnetic signal that disrupts the normal transmission of power or data. Sources of interference may include nearby electrical equipment, radio frequency emissions, or electromagnetic fields, and are commonly reduced through shielding and proper cable design.

Interstices

Interstices are the small spaces or voids between individual wire strands in a stranded conductor or between insulated conductors within a multiconductor cable. These spaces are often filled with fillers or other materials to improve cable shape, flexibility, and mechanical stability.

Intra Pair Skew

Intra pair skew is the difference in signal propagation time between the two conductors of a twisted pair. Excessive skew can degrade high-speed data transmission by causing timing errors and reducing overall communication performance.

IR (Insulation Resistance)

Insulation resistance (IR) is the measure of a material’s ability to resist the leakage of electrical current through its insulation. It is typically measured in megaohms (MΩ) or gigaohms (GΩ), with higher insulation resistance indicating better electrical isolation and cable integrity.

Irradiation

Irradiation is a manufacturing process in which insulation materials are exposed to high-energy electron beams or other forms of radiation to create cross-links between polymer molecules. This process improves heat resistance, mechanical strength, chemical resistance, and overall durability of cable insulation.

ISO (International Organization for Standardization)

The International Organization for Standardization (ISO) is an independent international organization that develops globally recognized standards for quality, safety, efficiency, and consistency. ISO 9001:2015 certification demonstrates that an organization maintains a quality management system focused on continuous improvement and customer satisfaction.

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Jacket

A jacket is the outer protective covering of a wire or cable that surrounds the insulated conductors and internal components. Cable jackets protect against abrasion, moisture, chemicals, sunlight, impact, and other environmental hazards while providing additional mechanical strength and durability.

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k (Dielectric Constant)

The dielectric constant (k), also known as relative permittivity, is a measure of a material’s ability to store electrical energy in an electric field compared to a vacuum. Materials with lower dielectric constants generally provide faster signal transmission and lower capacitance, making them desirable for high-frequency cable applications.

KFT (Thousand Feet)

KFT is an abbreviation for one thousand feet (1,000 ft) and is commonly used in the wire and cable industry to specify cable lengths or express electrical properties such as resistance, capacitance, or attenuation per 1,000 feet. This is sometimes also abbreviated as MFT.

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Laminated Tape

Laminated tape is a tape material made by bonding two or more layers of different materials together to combine their individual properties. In cable construction, laminated tapes are often used for shielding, insulation, moisture barriers, and mechanical protection.

Lay Direction

Lay direction refers to the direction in which the spiral twist of a stranded conductor or cable progresses when viewed along its axis. A cable may have either a left-hand lay (S direction) or right-hand lay (Z direction), depending on the direction of the spiral pattern.

Lay Length

Lay length is the axial distance required for a stranded conductor or cabled wire component to complete one full revolution around the cable axis. The lay length affects cable flexibility, electrical performance, mechanical strength, and overall construction characteristics.

Leakage Current

Leakage current is the small amount of unwanted electrical current that flows through or across the surface of an insulating material. Excessive leakage current may indicate insulation deterioration, contamination, moisture intrusion, or potential safety concerns.

Life Cycle

A life cycle test evaluates how long a wire, cable, or component can operate before failure under controlled conditions. These tests are often accelerated by applying repeated mechanical, thermal, or electrical stresses to predict long-term reliability.

Litz Wire

Litz wire is a specialized stranded conductor made from two or more individually insulated magnet wires twisted or braided together. This construction reduces the skin effect and improves efficiency in high-frequency applications such as transformers, motors, and induction equipment.

Longitudinal Shield

A longitudinal shield is a conductive tape or layer applied lengthwise along the axis of a cable core. It provides electromagnetic shielding and helps protect signals from external interference while maintaining cable flexibility.

Low Loss Dielectric

A low loss dielectric is an insulating material that dissipates very little electrical energy when exposed to an electric field. Materials such as polyethylene and fluoropolymers are commonly used because their low dielectric loss improves signal quality and reduces transmission losses in high-frequency cables.

Low Noise Cable

A low noise cable is specifically designed to minimize unwanted electrical signals caused by mechanical movement, vibration, or physical stress. These cables are commonly used in sensitive applications involving small signals, instrumentation, medical equipment, and sensors.

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Magnetic Field

A magnetic field is the region around a moving electrical charge, current-carrying conductor, or magnet where magnetic forces can be detected. In electrical systems, magnetic fields are closely related to current flow and are important in motors, transformers, and electromagnetic devices.

MCM (Thousand Circular Mils)

MCM is a unit of conductor area equal to one thousand circular mils. It is commonly used to specify the size of large electrical conductors, with larger MCM values indicating greater conductor area and higher current-carrying capacity.

MFT (Thousand Feet)

MFT is an abbreviation for one thousand feet (1,000 ft) and is commonly used in the wire and cable industry to describe cable lengths and material quantities. This is also sometimes abbreviated as KFT.

MHz (Megahertz)

Megahertz (MHz) is a unit of frequency equal to one million cycles per second (1,000,000 Hz). It is commonly used to describe the operating frequency of communication systems, radio signals, and high-speed data transmission equipment.

Microphonics

Microphonics refers to unwanted electrical noise generated when mechanical vibrations or physical movement affect a cable or electronic component. Also known as triboelectric noise, microphonics can interfere with low-level signals and is minimized through specialized cable designs.

Mil

A mil is a unit of measurement equal to one thousandth of an inch (0.001 inch). It is commonly used to specify wire diameters, insulation thickness, and coating thickness in the wire and cable industry.

Mylar®

Mylar® is a DuPont trademarked polyester film made from polyethylene terephthalate (PET). It is commonly used in cable manufacturing as a dielectric insulation layer, shielding tape, or protective wrap because of its strength, dimensional stability, and electrical properties.

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NE-F1

NE-F1 is New England Wire Technologies’ Class F electrical insulation system rated for operation at temperatures up to 155°C. It is designed for use in electrical components such as transformers, motors, and coils where reliable high-temperature insulation performance is required.

NEC (National Electrical Code)

The National Electrical Code (NEC) is a widely adopted safety standard published by the National Fire Protection Association (NFPA) that provides requirements for electrical wiring and equipment installation. The NEC is used throughout the United States to help ensure safe electrical systems and reduce fire and shock hazards.

NEMA (National Electrical Manufacturers Association)

The National Electrical Manufacturers Association (NEMA) is an organization that develops standards for electrical equipment, components, and systems used in industrial, commercial, and residential applications. NEMA standards help ensure product safety, reliability, and compatibility across manufacturers.

NEWcel®

NEWcel® is a closed-cell foamed dielectric material developed by New England Wire Technologies to improve cable performance by reducing dielectric constant and dissipation factor. It enables the production of low-capacitance, low-loss coaxial, triaxial, and twinaxial cables with improved signal transmission characteristics.

NEWind®

NEWind® is a specialty winding wire developed by New England Wire Technologies to reduce the need for additional grounding, inter-winding, and turn insulation in motors and transformers. Its design can help reduce component size, simplify manufacturing, and improve efficiency.

NEWtral®

NEWtral® is a low-noise cable technology developed by New England Wire Technologies to reduce electrical noise caused by mechanical shock and vibration. It is designed for small-signal applications where maintaining signal accuracy and reliability is critical.

NEWtuf®

NEWtuf® is a proprietary silicone rubber jacket developed by New England Wire Technologies. It provides high axial tensile strength, flexibility, and high-temperature performance for demanding cable applications.

NEXT (Near End Crosstalk)

Near End Crosstalk (NEXT) is a measurement of unwanted signal interference between pairs of conductors measured at the same end of the cable as the signal source. It is typically expressed in decibels (dB), with higher values indicating better resistance to crosstalk.

Noise

Noise is any unwanted or unintelligible electrical signal that interferes with the intended signal being transmitted through a cable or circuit. Noise can be caused by electromagnetic interference, mechanical movement, nearby electrical equipment, or other environmental factors, and is reduced through proper shielding and cable design.

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OD (Overall Diameter)

Overall diameter (OD) is the total outside diameter of a finished wire or cable, including all insulation, shielding, and jacketing layers. This measurement is important for determining installation requirements, bend radius, and compatibility with connectors or conduits.

OFHC (Oxygen Free High Conductivity Copper)

Oxygen-Free High-Conductivity (OFHC) copper is a highly refined copper material containing a minimum of 99.95% copper with extremely low oxygen content. It provides excellent electrical conductivity, typically exceeding standard copper conductivity levels (101% average conductivity in the annealed state), and is commonly used in applications requiring high purity and reliable electrical performance.

 

Ohm

The ohm (Ω) is the unit used to measure electrical resistance. One ohm is the resistance that allows a current of one ampere to flow when a voltage of one volt is applied across a conductor.

Overlap

Overlap is the amount by which the edge of a tape layer extends over the previous edge during a tape wrap process. It is typically expressed as a percentage and helps ensure continuous coverage, insulation integrity, and protection against environmental exposure.

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P/I (Picks Per Inch)

Picks per inch (P/I) refers to the number of times braid strands cross each other within one inch of cable length. A higher picks-per-inch value generally indicates a denser braid pattern with improved mechanical protection and shielding coverage.

Patch Cable

A patch cable is a flexible cable assembly with connectors installed on both ends that is used to connect electronic devices, network equipment, or circuits. Patch cables are commonly used in patch panels, test equipment, and communication systems where frequent connections and disconnections are required.

PE (Polyethylene)

Polyethylene (PE) is a thermoplastic material widely used in wire and cable applications because of its excellent electrical insulation properties, low dielectric constant, and high moisture resistance. It is available in different densities and formulations to provide varying levels of flexibility, strength, and durability.

PEEK (Polyether Ether Ketone)

Polyether Ether Ketone (PEEK) is a high-performance thermoplastic known for its exceptional mechanical strength, chemical resistance, and ability to withstand extreme temperatures. It is used in demanding wire and cable applications such as aerospace, medical equipment, and industrial environments.

Perfect Conductivity

Perfect conductivity refers to the theoretical condition where a material has zero electrical resistance. In wire and cable specifications, conductivity is often compared as a percentage of copper conductivity, with pure annealed copper representing the standard reference value.

PET (Polyethylene Terephthalate)

Polyethylene terephthalate (PET) is a strong and dimensionally stable polyester material commonly used in cable tapes, insulation films, and protective layers. It provides excellent mechanical strength, chemical resistance, and electrical insulating properties.

PFA (Perfluoroalkoxy)

Perfluoroalkoxy (PFA) is a fluoropolymer insulation material with excellent electrical properties, chemical resistance, weather resistance, and high-temperature performance. It is a melt-processible material often used in demanding applications requiring low friction, durability, and reliable insulation.

Pick

A pick is the distance along a braid where two opposing groups of strands intersect and then reach the next corresponding intersection. It is used to describe braid construction and influences the flexibility, coverage, and shielding effectiveness of a cable.

Pitch

Pitch is the distance between the same point on adjacent conductors in a flat cable arrangement. It is typically measured from the center of one conductor to the center of the next and is important for connector compatibility and cable spacing.

Plasticizer

A plasticizer is a chemical additive used to increase the flexibility, softness, and workability of plastic materials. In cable insulation and jackets, plasticizers help improve flexibility and durability, particularly in materials such as PVC.

Plenum Cable

Plenum cable is a cable approved for installation in air-handling spaces such as building plenums without requiring additional conduit. These cables use low-smoke and flame-resistant materials to reduce fire hazards and toxic emissions in occupied buildings.

Polyamide

Polyamide is a family of polymers containing repeating amide groups and is commonly associated with nylon materials. Polyamides are valued for their strength, abrasion resistance, durability, and resistance to many chemicals.

Polyimide

Polyimide is a high-temperature insulation material available in tape and film coating forms for specialty wire applications. It provides excellent thermal stability, mechanical strength, and resistance to radiation and chemicals.

Polymer

A polymer is a material made of long chains of repeating molecular units called monomers. Polymers form the basis of many insulation and jacket materials used in wire and cable manufacturing, including plastics, rubbers, and elastomers.

Polyolefin

Polyolefin is a family of polymers derived from olefin hydrocarbons, including polyethylene and polypropylene. These materials are commonly used in cable insulation and jackets because of their electrical properties, chemical resistance, and durability.

PP (Polypropylene)

Polypropylene (PP) is a thermoplastic similar to polyethylene but with greater stiffness and a higher softening temperature. It is commonly used as cable insulation where thin walls, low dielectric loss, and mechanical strength are required.

Primary Insulation

Primary insulation is the first layer of insulating material applied directly around a conductor to electrically isolate it from other conductors or external components. It provides the main protection against current leakage, short circuits, and electrical breakdown.

PU (Polyurethane)

Polyurethane (PU) is a group of polymers known for excellent abrasion resistance, flexibility, solvent resistance, and memory properties. It is frequently used as a cable jacket material, especially for retractile cords and applications requiring repeated movement.

Put-Up

Put-up refers to the method used to package finished wire or cable for storage, transportation, and installation. Common put-up formats include reels, spools, coils, and cut lengths depending on the product requirements.

PVC (Polyvinyl Chloride)

Polyvinyl chloride (PVC) is a widely used thermoplastic material that can be formulated to be either rigid or flexible. In wire and cable applications, PVC provides good insulation, flame resistance, mechanical protection, and cost effectiveness.

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Rated Temperature

Rated temperature is the maximum continuous operating temperature at which an electrical component, wire, or cable can function safely without excessive degradation or failure. This rating is determined by the materials used and ensures reliable performance throughout the expected service life of the product.

Rated Voltage

Rated voltage is the maximum voltage that an electrical component or cable is designed to withstand during continuous operation without insulation failure or safety concerns. Operating within the rated voltage helps prevent electrical breakdown, overheating, and premature equipment failure.

REACH

Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) is a European Union regulation that controls the production, use, and handling of chemical substances to protect human health and the environment. It requires manufacturers and importers to evaluate and manage risks associated with chemicals used in products and materials.

Reactance

Reactance is the opposition that capacitance and inductance present to alternating current (AC) flow. Unlike resistance, reactance depends on the frequency of the electrical signal and can either increase or decrease depending on whether the circuit contains inductive or capacitive elements.

Resistance

Resistance is the opposition a material provides to the flow of electrical current and is measured in ohms (Ω). In direct current (DC) circuits, resistance directly limits current flow, while in alternating current (AC) systems it contributes to the real component of impedance.

Retractile Cable

A retractile cable is a coiled cable designed to stretch and return to its original compact shape through stored mechanical energy. These cables are commonly used in applications such as telephone cords, medical equipment, tools, and portable electronic devices where flexibility and space savings are important.

Return Loss

Return loss is a measurement of the amount of electrical signal power reflected back toward the source due to impedance mismatches or discontinuities in a cable system. Higher return loss values indicate better signal transmission because less energy is reflected.

RFI (Radio Frequency Interference)

Radio Frequency Interference (RFI) is unwanted electromagnetic energy within the radio frequency range that can disrupt electrical signals or equipment operation. Shielding, grounding, and proper cable design are commonly used to reduce RFI.

Ribbon Cable

Ribbon cable is a flat cable consisting of multiple individually insulated conductors arranged parallel to one another and bonded together. It is commonly used in computers, electronic equipment, and control systems where compact, organized connections are required.

 

Rip Cord

A rip cord is a strong fiber or filament placed beneath a cable jacket to assist in removing the outer covering during installation. Pulling the rip cord creates a controlled split in the jacket, allowing easier access to the internal conductors.

RoHS (Restriction of Hazardous Substances)

RoHS is a European directive that restricts the use of certain hazardous materials in electrical and electronic products. The regulation limits substances such as lead, mercury, cadmium, and other harmful materials to reduce environmental and health risks.

Ropelay Cable

Ropelay cable is a cable construction made by arranging multiple groups of wires helically around a central core, creating a structure similar to a rope. This design provides increased flexibility, strength, and durability for demanding mechanical applications.

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SAE (Society of Automotive Engineers)

SAE International is a professional organization that develops standards for automotive, aerospace, and transportation industries. SAE standards help ensure compatibility, safety, reliability, and performance of vehicles, components, and related systems.

Serve

A serve is a filament, wire, or group of fibers wound helically around a cable core to provide insulation support, mechanical protection, or shielding.

Shield

A shield is a conductive layer made from tape, wire, foil, or other materials that surrounds a conductor or cable to reduce electromagnetic interference (EMI) and prevent signal leakage. Shielding improves signal quality by blocking unwanted electrical noise from entering or leaving the cable.

Shield Coverage

Shield coverage is the percentage of a cable’s surface area that is physically covered by shielding material. Higher shield coverage generally provides better protection against electromagnetic interference, although shielding effectiveness also depends on the shield design and grounding method.

Signal Integrity

Signal integrity refers to the quality and reliability of an electrical signal as it travels through a cable or system. It includes factors such as signal loss, distortion, noise, impedance matching, and timing accuracy, which are especially important in high-speed data applications.

Silicone Rubber

Silicone rubber is a flexible insulation and jacketing material made from silicone, oxygen, and other chemical elements. It provides excellent high-heat resistance, excellent electrical insulation properties, weather resistance, ozone resistance, radiation resistance, and low moisture absorption.

 

Skin Effect

Skin effect is the tendency of alternating current (AC) to flow primarily along the outer surface of a conductor as frequency increases. This effect increases the effective resistance of the conductor at high frequencies and influences cable design for high-speed applications.

SLEEK™

SLEEK™ is a New England Wire Technologies trademarked silicone-based material applied during manufacturing to provide a smooth, low-friction surface on silicone rubber insulated cables. It improves handling, ease of installation, and is highly resistant to debris while maintaining silicone’s high-temperature performance.

Spark Test

A spark test is a quality-control test used to detect small defects, pinholes, or breaks in cable insulation. A high voltage is briefly applied while the cable passes through an electrode field, allowing imperfections in the insulation to be identified.

Specific Gravity

Specific gravity is the ratio of a material’s density (mass per unit of volume) compared to the density of water. It is commonly used to compare the weight characteristics of insulations, jackets, and other cable materials.

 

Splice

A splice is a connection made by joining two or more conductors, typically from separate cable sections or assemblies. Properly designed splices maintain electrical continuity while providing mechanical strength and environmental protection.

Stranded Conductor

A stranded conductor is made by combining multiple smaller wires twisted together to form a larger conductor. Stranding improves flexibility compared to solid conductors while maintaining good electrical conductivity.

Strip Force

Strip force is the amount of force required to remove insulation or jacketing material from a conductor. Proper strip force ensures easy termination without damaging the conductor.

SVHC (Substance of Very High Concern)

A Substance of Very High Concern (SVHC) is a chemical substance identified under the REACH regulation as presenting significant risks to human health or the environment. Products containing SVHCs above certain concentrations may require reporting, notification, or restrictions within the European Union.

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Temperature Rating

Temperature rating is the maximum continuous operating temperature at which an insulating material can function without losing its essential electrical, mechanical, or physical properties. Exceeding the temperature rating can cause insulation breakdown, reduced performance, and premature cable failure.

Tensile Strength

Tensile strength is the maximum pulling force a material can withstand before breaking or permanently deforming. In wire and cable applications, tensile strength is used to evaluate the mechanical durability of conductors, insulation, and jackets during installation and operation.

TFE (Tetrafluoroethylene)

Tetrafluoroethylene (TFE) is a high-performance thermoplastic fluoropolymer known for its excellent electrical insulation, chemical resistance, and heat resistance. TFEs can operate continuously at temperatures up to approximately 260°C, making it suitable for demanding aerospace, industrial, and electronic applications.

Thermocouple

A thermocouple is a temperature-sensing device made from two different metals joined together at one or more points. When exposed to a temperature difference, the metals generate a measurable voltage that can be used to determine temperature.

Thermoplastic

A thermoplastic is a polymer material that can be softened or melted by heating and re-hardened when cooled without significantly changing its chemical structure. This property allows thermoplastics to be easily processed and reused in manufacturing applications, including wire insulation and cable jackets.

Tinsel

Tinsel is a flexible conductor made from multiple threads wrapped with very thin, flat metal wires, typically copper or another conductive material. It is commonly used in small flexible cables, such as audio cords and retractile cables, where repeated bending and long flex- life are required.

TOC (Tin Overcoat)

Tin Overcoat (TOC) is a tinned copper conductor construction in which stranded copper wires are coated with an additional layer of tin. The tin coating improves corrosion resistance, solderability, and long-term reliability in electrical connections.

TPE (Thermoplastic Elastomer)

Thermoplastic Elastomer (TPE) is a material that combines the flexibility and elasticity of rubber with the processing advantages of thermoplastics. TPEs are commonly used for cable insulation and jackets because they provide flexibility, durability, and resistance to environmental conditions.

Transfer Impedance

Transfer impedance is a measurement of how effectively a cable shield prevents external electrical currents from creating unwanted voltages inside the cable. Lower transfer impedance indicates better shielding performance and improved protection against electromagnetic interference.

Triaxial Cable (Triax)

A triaxial cable is a variation of coaxial cable that contains a central conductor, an insulating dielectric layer, and two separate conductive shields. The additional shield provides improved protection against interference and is commonly used in video, measurement, and high-frequency signal applications.

Triboelectric Noise

Triboelectric noise is unwanted electrical noise generated when movement or vibration causes changes in capacitance between a cable’s conductor and shielding. It is commonly associated with flexible cables and is reduced through specialized low-noise cable designs.

Twinaxial Cable (Twinax)

Twinaxial cable is a communication cable consisting of two insulated conductors surrounded by a common conductive shield and protective outer jacket. Similar to coaxial cable, it provides controlled impedance and shielding but uses a pair of center conductors for differential signaling applications.

Twisted Pair

Twisted pairs refer to two insulated conductors twisted together at a consistent rate along their length. The twisting helps reduce electromagnetic interference and crosstalk, making twisted pairs widely used in telecommunications and data networks.

Twisted Triad

A twisted triad is a cable construction consisting of three individually insulated conductors twisted together. This design is commonly used in instrumentation, control systems, and applications requiring balanced signal transmission.

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UL (Underwriters Laboratories)

Underwriters Laboratories (UL) is an independent safety organization that develops standards and performs testing and certification for electrical products, materials, and systems. UL certification indicates that a product has been evaluated for safety and compliance with applicable standards.

Unilay

Unilay refers to a conductor construction where multiple layers of helically arranged wires have the same direction and length of lay. This design is cost-effective with improved flexibility and flex-life.

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VHF (Very High Frequency)

Very High Frequency (VHF) refers to frequencies between approximately 30 MHz and 300 MHz. Because VHF signals bounce and propagate differently than standard electrical currents, cables handling these frequencies require specific physical and electrical properties such as impedance matching, appropriate shielding, and low attenuation to minimize signal loss.

 

Volt

A volt (V) is the unit used to measure electrical potential difference or electromotive force. One volt is the amount of electrical pressure required to drive one ampere of current through a resistance of one ohm.

Voltage

Voltage is the electrical potential difference between two points in a circuit that causes current to flow. It represents the amount of electrical energy available per unit charge and is measured in volts (V).

Voltage Rating

Voltage rating is the maximum continuous voltage a wire, cable, or electrical component can safely withstand while meeting specified performance and safety requirements. Operating above the rated voltage can cause insulation breakdown, arcing, or equipment failure.

VOP (Velocity of Propagation)

Velocity of propagation is the speed at which an electrical signal travels through a cable compared to the speed of light in free space. It is expressed as a percentage and is influenced by the dielectric properties of the cable insulation.

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Wall

Wall refers to the thickness of insulation or jacketing material applied around a conductor or cable. Proper wall thickness ensures adequate electrical insulation, mechanical protection, and environmental resistance.

Watt

A watt (W) is a unit of electrical power which represents the rate at which electrical energy is used or transferred. In a direct current (DC) circuit, one watt equals one volt multiplied by one ampere.

Wicking

Wicking is the movement of liquid along the length of a wire or cable caused by capillary action between strands or layers. Moisture wicking can affect cable reliability by allowing water or other liquids to travel internally along the cable.

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Zip Cord

A zip cord is a cable construction consisting of two or more independently insulated conductors in a parallel configuration. The insulated conductors are bonded together but can be easily separated by pulling them apart, leaving the insulation of each conductor intact. The conductors may be extruded simultaneously or extruded independently and bonded together in a separate operation.