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7 Guidelines for Continuous Flex Cables

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7 Guidelines for continuous-flex cables For dynamic applications, the use of continuous-flex cables, such as the Chainflex ® range from igus ® , can increase service life and productivity dramatically when compared to traditional cables, which are prone to failures such as corkscrewing, shield/conductor breakage, or jacket abrasion and/or splitting. In this guide, learn the seven key design features that can ensure a continuous-flex cable will work for your application for millions of cycles - even in the most demanding environments. 1. Strain-relieving center element The center core should be filled with a high-quality, high tensile strength center element to protect twisted conductors from falling into the center of the cable. 2. Conductor structure The copper stranding in Chainflex ® continuous-flex cables is chosen in accordance with tested and proven designs. The test results from the igus ® lab indicate that a medium to fine conductor strand diameter is preferable. Many competitive cable manufacturers will employ an extra-fine conductor strand, which has the tendency to kink when subjected to a high number of cycles. Using findings from long-term cable testing, igus® uses a combination of conductor strand diameter, pitch-length, and pitch direction to achieve the best service life and performance, even in the most demanding applications. 3. Conductor insulation Insulation materials within the cable must be resistant to adhering to one another. The insulation must also support the stranded individual wides of the conductor. Only the highest quality high-pressure extruded PVC or TPE materials should be used. 4. Cable core Individual conductors are bundled into groups, which are cabled together in a single layer surrounding the cable core. This design enables pulling and compressive forces if the bending motion to balance and cancel out torsional forces. Special attention is given to pitch length and direction. The cable's inner jacket will also help to maintain the integrity of the cable core and provide a continuous surface for the shield. Learn more at

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