Design considerations and options for your custom configuration
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 Comparison: Interconnects vs. General Power Leads
| 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 |
Conductor Materials & Plating Selection
Conductor Options (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
Insulation Polymers & Stranding Specifications
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 & Stranding Characteristics:
- 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)
Engineers Ask: Power Leads & Flexible Interconnects FAQs
How much movement qualifies as “dynamic flex”?
In the world of wire and cable, dynamic flex refers to a cable that will see active, continuous motion, or flexing cycles. The cycle, duration, and frequency could all be different for various applications, but the cable will be flexed repeatedly in use, as opposed to static flex, which generally refers to the cable being flexed one time, usually for installation.
When does repeated motion require a purpose-designed interconnect?
Don’t confuse flexibility with high flex-life, as they are not the same. If you need a flexible interconnect for installation around tight bends or have a complex installation path, then a flexible interconnect is likely the answer. Just remember that materials and cable configuration that support flexibility don’t always mean the cable can withstand stressful, repeated flexing or bending cycles.
Does tight cable routing alone justify an ultra-flexible construction?
It certainly can. Imagine trying to route a stiff cable in a tight space with bends and turns when that cable acts like a piece of iron rebar! Your installer will not be happy! Don’t be that person. Instead, design in a flexible interconnect that will handle tight routings, sharp bends, and lay in that track like it was meant to be there.
