Custom Cables

Coast™ Custom Cable from Alpha Wire provides exceptional custom wire and cable creations by utilizing the latest extrusion equipment and expert design assistance.

The Right Cable... Just the Way You Want It

Alpha Wire’s custom manufacturing capabilities include an assortment of insulation materials, from PVC to PTFE to silicone, and a conductor range of 4/0 to 50 AWG. We also provide responsive prototyping and development, design/manufacturing assistance & feedback, and material selection.

Alpha Wire will work with you to optimize your design and our manufacturing process to attain cost, quality, and design objectives. As a result, you will get the best match of electrical, mechanical, and environmental properties for your specific application. Most importantly, minimum order sizes are as low as 100 feet, enabling you to only purchase what you need for prototyping.

How to Order:

Fill out this form in its entirety and include company name, address, phone number and contact information (state customer number with Digi-Key if available). Also note any options that may not be listed and send to AlphaWireCustoms@digikey.com.

*Upon acknowledgment of the request, we will quote accordingly.

Wire Images
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More Choice in Cable Configurations

Custom Engineered to Your Specifications and Designs

  • Multiconductor cables
  • Multipair cables
  • Microminiature cables
  • Coaxial cables
  • Microcoaxial cables
  • Hybrid cables
  • Composite cables
  • Power cables
  • Lead wires
  • Litz wires
  • Flat, ribbon, zip cables
  • Flat, round braids
  • Retractable coil cords
Cables Image

Conductor Materials

Conductors: 50 AWG to 4/0 AWG

Copper

  • Bare copper
  • Tinned copper
  • Silver-plated copper
  • Nickel-plated copper
  • Copper alloys

Specialty

  • Magnet wire
  • Tinsel wire
  • Thermocouple wire

Precious Metals and Alloys

  • Silver, platinum, gold
  • Other exotic materials

Fibers and Yarns

  • Carbon fiber (0.5K – 12K)
  • Metalized carbon fiber
  • Aramid fiber
  • Stainless steel yarn

Insulating and Jacketing Compounds

Fluoropolymers

  • PTFE
  • FEP
  • PFA
  • ETFE
  • PVDF

Rubbers

  • Neoprene
  • Thermoplastic vulcanite
  • Melt-processible rubber

Silicones — Thermosets

  • Silicone
  • Flame-retardant silicone
  • High-voltage silicone

Thermosets

  • XLPE

Thermoplastics

  • PVC, SR-PVC
  • PP
  • PE
  • PUR
  • Nylon
  • TPE
  • TPR
  • TPA
  • mPPE
 

Shielding

Application:

  • Overall and individual conductors/pairs

Types

  • Foil
  • Braid
  • Spiral
  • Supra-Shield® foil + braid
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More Custom Options

Flexing

Flex Types

  • Rolling
  • Bending
  • Torsional
  • Continuous

Flex Cycles

  • Up to 20 Million

Ratings

Electrical

  • 30 V
  • 150 V
  • 300 V
  • 600 V
  • 1000 V up to 75k V

Temperature

  • -80º to +450ºC

Approvals

Mechanical/Environmental

  • UL
  • CSA
  • CE
  • IEC
  • ISO USP Class VI
  • ISO 10933 RoHS
  • REACH
  • Abrasion resistance
  • Oil resistance
  • Chemical/solvent resistance
  • Sunlight resistance
  • Sterilizable
  • Low outgassing

Packaging

Other:

  • Reeled in small or large put ups
  • Cut to length
  • Custom printing
  • Custom jacket colors
  • 100’ or 1000’ minimum order
  • Can design custom cables with lumens.

Manufactured Products

Value-Added Capabilities

  • Cable assembly with Tier 2 partners
  • Coil cords
  • Custom packaging
  • Cut-to-length
  • Dying
  • Etching
    • Non-chemical
    • PTFE materials
    • Connector end for assembly
  • Marking
  • Spooling (UL, CSA)
  • Striping
  • Stripping
  • Tinning
  • Twisting
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