Flat and ripcord cable constructions are used when routing constraints, flexibility, or conductor organization require alternatives to traditional round cable designs. These constructions prioritize consistent geometry, controlled separation, and reliable mechanical performance.

Flat Cable Constructions

Flat cables arrange conductors in a single plane or bonded ribbon configuration.

  • Bonded ribbon constructions with two or more conductors
  • Uniform spacing for consistent electrical performance
  • Reduced profile for tight routing and stacking applications
  • Available with high strand-count copper, copper alloy, or tinsel conductors

Flat cables may be shielded, jacketed, or constructed as multi-conductor assemblies depending on application requirements.

Ripcord Constructions

Ripcord designs combine multiple insulated conductors into a connected profile that can be separated as needed.

  • Round, figure-eight, double-D, or custom profiles
  • Shared or individual jackets
  • Flexible separation during termination or installation
  • Maintains mechanical alignment during use

Ripcord constructions balance flexibility with controlled conductor organization.

Mechanical and Dimensional Considerations

Construction choice affects size, flexibility, and durability.

  • Overall width and thickness vary by conductor count and insulation wall
  • Flat profiles reduce stacking height but increase bend-plane sensitivity
  • Ripcord designs support controlled separation without sacrificing strength

Material selection influences flex life and handling characteristics.

Typical Applications

Flat and ripcord constructions are commonly used in:

  • Medical and diagnostic equipment
  • Industrial controls and instrumentation
  • Communications and audio assemblies
  • Specialty and space-constrained applications

Engineering Support

Flat and ripcord designs require careful coordination of materials, geometry, and termination requirements. Gavitt works with customers to evaluate space constraints, motion demands, and performance goals to develop appropriate constructions.