SuperFlex conductors are engineered for applications requiring exceptional flexibility and long service life under repeated bending. High strand counts, fine-gauge conductors, and soft insulation systems work together to minimize mechanical stress and extend fatigue life.
SuperFlex Conductor Construction
SuperFlex designs use very high strand counts of fine copper wire to achieve extreme limpness.
- Soft bare or tinned copper
- Typical sizes from 36 AWG through 44 AWG
- Bunched or rope-lay constructions
- Low mechanical stress during repeated motion
High-Strength Alloy Options
Copper alloy conductors are available for applications requiring added durability.
- Increased fatigue resistance
- Improved tensile strength
- RoHS-compliant alloy options
Tinsel Conductors
For the highest flex-life requirements, tinsel conductors may be used.
- Metal ribbons wound around a textile core
- Exceptional flexibility and fatigue resistance
- Typically used in low-current applications
Insulation and Flex Performance
Soft insulation compounds are essential to SuperFlex performance.
- PVC and thermoplastic rubber formulations
- Thin wall constructions to reduce stiffness
- Maintains flexibility over repeated flex cycles
Typical Applications
- Medical lead wires
- Communications and headset cables
- Retractile cords and assemblies
- Continuous-motion or high-flex environments
Selecting a SuperFlex Design
Flex-life performance depends on conductor type, strand geometry, insulation material, and application conditions. Gavitt works with customers to identify the most appropriate SuperFlex construction for each use case.
Our use of planetary winders also contribute to longer flex life of cables.