flexwires

Flexwires are flexible electrical conductors designed to withstand repeated bending and motion without compromising conductivity or insulation. They are used in applications where wiring must endure frequent flexing, twisting, or vibration, such as robotics, wearable devices, automotive harnesses, and compact consumer electronics.

Construction and materials: A flexwire typically consists of a stranded copper conductor, sometimes with tinsel or fine-wire strands to maximize flexibility, insulated with a flexible polymer such as PVC, thermoplastic elastomer (TPE), silicone, or fluorinated polymers. The insulation is protected by an outer jacket made from PVC, rubber, or silicone compounds. Conductors are rated by gauge and current; flex wires emphasize low torsion stiffness and high bend resilience. Flex life is defined by the number of bending cycles the wire can endure before insulation or conductor damage.

Configurations: Flexwires come as single-core flexible wires, multiconductor bundles, or as flat flexible cables (FFCs) and other cable assemblies. They may include shielding or multiple insulation layers for signal integrity and durability.

Applications and performance: They are used inside devices to connect moving parts, in test equipment, medical devices, and robotics. Temperature ratings vary with material, often ranging from -40 to 125 degrees Celsius in industrial-grade parts. Flex wires are designed to minimize kinking and maintain electrical performance under repeated flexing while meeting safety and insulation standards.

Standards and safety: Manufactures typically design flexwires to comply with applicable electrical insulation and safety standards (for example, general insulated conductor standards) and specify bend radii and flex-life guidelines. Proper strain relief and routing are essential to prevent damage during installation.

See also: Wire, Cable, Flexible electronics.