Complete Guide to Engineered Materials — Filament and Cable Coating

July 20, 2023 | Blog

Material selection becomes crucial in the modern marketplace, where product performance and safety are paramount. Automotive, aerospace, telecommunications, and power transmission industries recognize the importance of optimized filament and cable coating in achieving superior results. These engineered materials can revolutionize product design, boost performance, and ensure the highest level of safety.

At Terrafilum, we specialize in delivering special filaments to our valued customers! We take pride in upholding stringent quality control measures, ensuring that every product meets the highest standards of excellence. We also have a dedicated customer service team to provide support, ensuring a seamless partnership with our customers.

Engineered Filaments: Definition and Characteristics

Engineered filaments, or synthetic or engineered fibers, refer to materials specifically designed and manufactured to possess desired properties. These filaments comprise polymers or other synthetic materials such as polyester, nylon, carbon fiber, and aramid. They are also created through various manufacturing processes such as melt, dry, or wet spinning.

One of the key characteristics of engineered filaments is their tailored physical and chemical properties. Manufacturers can customize the material’s properties, such as strength, flexibility, thermal resistance, electrical conductivity, and chemical stability. This makes them highly versatile in the aerospace, automotive, electronics, and healthcare industries.

Engineered filaments also often exhibit superior performance compared to natural fibers. They can possess higher tensile strength, better resistance to wear and tear, improved moisture management, and enhanced durability. Additionally, they can be designed to be lightweight, making them suitable for applications where weight reduction is crucial.

Types of Engineered Filaments

There are various categories of engineered filaments used in different industries and applications. Each of the following types has unique properties for specific industrial needs:

Aramid Fibers

Aramid fibers are a category of high-performance synthetic fibers distinguished by their exceptional strength, heat resistance, and flammability. They comprise long chains of repeating aromatic units linked by amide bonds. Their use in critical protective gear and reinforcement of materials has improved safety standards and performance in various industries.

Biodegradable Filaments

When exposed to environmental conditions, biodegradable filaments are designed to degrade and break down into natural components. Some are derived from renewable resources such as corn starch, sugar cane, or other plant-based materials. Using these renewable resources as raw materials helps decrease reliance on fossil fuels and reduces the carbon footprint associated with filament production.

Carbon Fibers

Carbon fibers are composed of carbon atoms bonded together in a crystal-like structure. They offer exceptional strength, stiffness, and lightweight properties. They are also widely used in aerospace, automotive, sporting goods, and construction industries, requiring high-performance and light materials.

Conductive Filaments

Conductive filaments are designed to possess electrical conductivity. They typically incorporate a base polymer blended with conductive additives or infused with metallic materials. As they can be used in 3D printers with extruders, they also allow for the incorporation of electrical functionality into 3D-printed objects.

Optical Fibers

Optical fibers are thin, flexible, transparent filaments made of high-quality glass or plastic. They transmit light signals over extended distances with minimal signal loss and distortion. They also have a much larger bandwidth than traditional copper cables, enabling them to carry vast data. This makes them popular in telecommunications, medical imaging, and sensing applications.

Engineered Cable Coatings: Definition and Characteristics

Engineered cable coatings refer to specialized protective coatings applied to cables to enhance their performance, durability, and reliability. They are designed to provide a range of characteristics and properties that suit the specific requirements of different cable applications. In addition, they are often composed of polymers or other synthetic materials and are applied through various coating processes.

These specialized coatings possess a significant attribute of offering electrical insulation, achieved through their formulation with high dielectric strength. This property enables them to efficiently obstruct the movement of electric current within the cable’s conductive components. The insulation offered is also critical for maintaining good electrical performance and preventing short circuits.

Furthermore, engineered cable coatings resist environmental influences like moisture, chemicals, abrasion, and UV radiation. They act as a barrier, protecting the cable’s internal components from potentially damaging factors. Cable coatings can also improve mechanical attributes, including flexibility, tensile strength, and impact resistance.

Types of Engineered Cable Coatings

Various engineered cable coatings are available, each designed to provide specific characteristics. Manufacturers select the appropriate layer based on the desired properties and the cable’s intended use. Discussed below are examples of the most common types of engineered cable coatings:

Polyethylene (PE) Coatings

PE coatings exhibit good flexibility, allowing the coated cables to bend and withstand mechanical stresses without cracking. This makes PE-coated lines easier to handle and install, especially in applications requiring cable routing around obstacles or tight spaces. They also have a relatively low dielectric constant, which is beneficial for high-frequency signal transmission.

Cross-Linked Polyethylene (XLPE) Coatings

XLPE coatings have excellent thermal stability, allowing them to withstand high temperatures without degradation. They can operate at elevated temperatures for extended periods without compromising their electrical and mechanical properties. They also resist various chemicals, including acids, bases, and solvents.

Polyvinyl Chloride (PVC) Coatings

PVC coatings are highly versatile and can be applied to various cable types and sizes. They are suitable for low-voltage and medium-voltage cables used in multiple industries such as construction, power distribution, telecommunications, and automotive. PVC is also a low-cost material than other cable coating options.

Fluoropolymer Coatings

Fluoropolymer coatings have a low coefficient of friction, resulting in reduced surface friction and enhanced lubricity. This property allows cables coated with fluoropolymers to move smoothly and reduce wear and tear. Moreover, they are lightweight and can be applied as thin layers while maintaining their performance properties.

Silicone Coatings

Silicone coatings exhibit good resistance to UV radiation and weathering. They can withstand prolonged exposure to sunlight without significant degradation or loss of performance. This UV resistance suits them for outdoor and solar applications, where cables are exposed to direct sunlight. They can also maintain their integrity in both hot and cold conditions.

Selection Criteria for Engineered Filaments and Cable Coatings

When choosing filaments and cable coatings, several key criteria should be considered to ensure the best fit for the application. Gathering information from material suppliers, conducting testing or trials when necessary, and consulting with experts are also important. This will help make informed decisions that result in successful and reliable cable solutions.

Here are four essential selection criteria:

Application-Specific Requirements

It is crucial to determine the application’s specific requirements in terms of electrical, mechanical, and environmental performance. Considerations include required electrical insulation, temperature resistance, flexibility, chemical resistance, UV stability, and moisture resistance. This will help match the material qualities to the application, ensuring optimal performance and reliability.

Longevity and Durability

Assessing the material’s expected lifespan and durability can provide valuable insights into its performance and suitability for the application. This includes evaluating the filament’s resistance to wear, environmental degradation, and mechanical stresses. It will also be easier to choose materials that can provide long-lasting performance, ultimately helping to minimize maintenance.

Manufacturing and Processing Considerations

Evaluating the feasibility and compatibility of the filament and coating with the manufacturing and processing methods can facilitate efficient production. It is crucial to consider factors such as compatibility with extrusion processes and ease of handling and installation. It is also beneficial to look at the bonding procedures and any particular post-processing or finishing requirements.

Terrafilum for Reliable and High-Quality Engineered Filaments

At Terrafilum, we take pride in our role as a leading provider of top-of-the-line, eco-friendly 3D printing filament solutions! Our extensive range of filaments caters to customers across diverse industries, offering tailored solutions for projects of all sizes and complexities. Furthermore, we are proud to be a US-based manufacturer that follows stringent quality control measures.