Wire and Cable

Custom wire and cables are tailored electrical conductors designed to meet specific requirements for various applications. Unlike standard options, which are mass-produced and available in common sizes and specifications, custom wire and cable solutions are made to fit unique needs. The manufacturing process includes detailed design consultation, precise material selection, and rigorous testing to ensure compliance with performance standards and application needs.

Micro-Tek Corporation is a trusted manufacturer of bespoke wire and cable solutions for diverse applications. With decades of experience and a commitment to precision, our expert team works closely with clients to ensure that every product meets their specific needs.

Industries Leveraging Custom Wires and Cables

Custom wire and cable solutions are essential in various industries, ensuring optimal performance and reliability. They are beneficial in the following sectors:

  • Aerospace: Custom wire and cables endure extreme conditions like high temperatures and vibrations, ensuring reliable performance in avionics, navigation, and communication systems.
  • Military and defense: Bespoke cables meet strict durability standards for communication, weaponry, and critical systems, ensuring reliable operation in harsh environments.
  • Medical: Specialized wires and cables enhance the precision and safety of diagnostic equipment, patient monitoring systems, and surgical instruments.
  • Audio: High-quality custom cables are essential for clear sound and durability in recording, broadcasting, and live performances.
  • Computer: Custom cables ensure efficient data transfer and power distribution across components like processors, memory, and peripherals.
  • Automotive: Bespoke cables are vital for engine control, navigation, infotainment, and safety features, providing reliable performance in tough conditions.
  • Electronics: Custom wire and cables support consumer electronics, industrial equipment, and communication devices, ensuring reliable connections and efficient power management.
  • RF/Microwave: Customized cables facilitate high-frequency signal transmission with minimal loss for communication systems and radar applications.

Custom Wire and Cable Capabilities at Micro-Tek

Micro-Tek Corporation excels in providing custom wire and cable solutions with a broad range of capabilities:

General Capabilities

We offer flexible and precise custom wire and cable manufacturing to meet diverse industry needs. Our offerings capabilities include:

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  • As-needed production: Custom solutions are provided based on specific customer demands, allowing flexibility in meeting varying requirements and adapting to changing needs.
  • Contract manufacturing: We provide contractual production agreements, which establish long-term partnerships and a consistent supply of custom wires and cables.
  • Just-in-time (JIT) production: Our JIT production strategy minimizes inventory costs and reduces waste by delivering products precisely when needed.
  • On-site production: We offer on-site production services for specialized needs. This allows for the customization of products directly at the client’s location.

Products

We specialize in a variety of custom wire and cable products designed to meet the specific needs of various industries:

  • Lead/hook-up wire: versatile and reliable for general-purpose electrical connections
  • Micro coaxial cables: ideal for high-frequency signal transmission with minimal interference
  • Multi-conductor cables: provide organized and efficient wiring solutions for complex systems
  • Medical grade flat wire: designed for medical devices, offering precise performance and durability
  • Medical grade insulated round wire: ensures safety and reliability in medical applications
  • Teflon® PTFE tubing: high-temperature and chemical-resistant tubing for demanding environments
  • Uninsulated wire: suitable for applications requiring direct electrical connectivity
Extruded PTFE Tubing and Liner
Braid Wire

Wire Materials

Micro-Tek uses a variety of materials to ensure optimal performance and durability, including:

  • Silver plated copper: excellent conductivity and corrosion resistance
  • Bare copper: versatile and cost-effective for general electrical applications
  • Copper-based alloys: enhanced strength and resistance to wear and tear
  • Stainless steel (304 and 316L): superior durability and resistance to corrosion and high temperatures
  • Resistance wire: precise control of electrical resistance for specialized applications
  • Nickel-plated copper: combines conductivity with enhanced corrosion resistance
  • Specialty/precious metals on toll: customized solutions for unique requirements

Insulation Materials

We use the following high-performance insulation materials to enhance wire and cable functionality:

  • Chemours fluoropolymer resin: provides superior chemical resistance and durability
  • Teflon® PTFE: high-temperature and chemical-resistant insulation
  • Teflon® FEP: excellent electrical properties and resistance to high temperatures
  • Teflon® PFA: high-performance insulation for extreme environments
  • Tefzel® ETFE: strong resistance to chemicals and high temperatures
  • Other resins may be available
Toll Manufacturing
High Performance Coax Core

Specifications

Micro-Tek offers a wide range of specifications to meet customer needs:

  • AWG: 18 AWG to 50 AWG
  • Insulated wire diameter and thickness: Min – .010″, Max – .250″
  • PTFE thickness: Min – .0035″
  • FEP/PFA/ETFE thickness: Min – .00075″
  • Finished wire product tolerance: Outer diameter can be held to ±.0002″ for insulated wire and ±.0002″ for flat wire

Lead Time

We typically offer lead times of 3 to 4 weeks, ensuring timely delivery for custom and standard orders.

Our Specialty Products

Micro-Tek provides a range of specialty products designed to meet specific industry requirements with precision and reliability:

High Performance Coax Core

Customized core to facilitate high-frequency signal transmission with minimal loss for communication systems and radar applications. Insulation materials include:

  • Solid PTFE (69% VP Nom)
  • LD-Tek Low Loss PTFE (77% VP Nom)
  • Phas-Tek Phase Stable (76-82% VP Nom)
  • Vel-Tek High Velocity PTFE (80-88% VP Nom) (In Development)

In addition to the above materials, Micro-Tek has the ability to create custom products with other fluoropolymers to meet a customer’s requirement.

Sub-Miniature Hook-up Wire

Our sub-miniature hook-up wire is perfect for applications where space and precision are critical. These wires are designed to meet stringent requirements for reliability and performance in compact systems.

Custom Flat Wire for the Medical Device Industry

Micro-Tek manufactures custom flat wire using premium alloys such as 304 VMSS and 316SS. These wires are produced to exact tolerances, with standard tolerances of ±10% for width and thickness. They are available in high volumes to support global medical device needs.

Custom Stranding for the Medical Industry

Our custom stranding solutions cater to the unique needs of the medical sector, providing wires with the necessary flexibility and performance. This includes stranding configurations to meet stringent industry standards.

Micro-Coaxial Cable for the Sensor Industry

Micro-Tek’s micro-coaxial cables are designed for low-noise applications and used in sensitive sensor environments. These cables are often configured with silver-plated copper and feature custom insulation and shielding. We handle orders with a minimum requirement of 5000 feet and offer an eight-week lead time.

Thermocouple Wires

We provide a range of thermocouple wires, including types K, J, and T. These wires are available with various insulation materials like PTFE, PFA, and FEP, making them suitable for high-temperature and extreme environment applications. We also offer multiple constructions, including single insulated strands, twisted pairs, parallel pairs, jacketed and over braided cables

High Flex Braided Cable for the Sensor Industry

Our high-flex braided cables are engineered to withstand low-pressure and low-temperature environments (cryogenic?). They feature FEP insulation and customizable colors, making them ideal for applications requiring superior flexibility and durability.

Shielded Twisted Pair Cable for the Aerospace Industry

We manufacture shielded twisted pair cables designed to reduce electromagnetic interference in aerospace applications. These cables are insulated with Teflon® PTFE, wrapped with Kapton® tape, and shielded with silver-plated copper. They undergo rigorous testing to meet the demanding conditions of aerospace environments.

Partner With Micro-Tek for Precision Wire and Cable Solutions!

With decades of experience and a commitment to excellence, Micro-Tek Corporation is your go-to provider for high-precision, tailor-made electrical conductors. Our advanced manufacturing capabilities ensure that every product adheres to stringent performance requirements.

We specialize in a diverse range of products, each with carefully selected materials and advanced insulation options for optimal performance and durability. Our expert team also excels in various services, including drawing, stranding, tape wrapping, etching, cutting, stripping, and tinning.

Contact us or request a quote today to get started!

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Custom Wire And Cables Capabilities

General Capabilities

As Needed
Contract
Just-In-Time
On-Site Production

Products

Lead / Hook-up Wire
Micro Coaxial Cables
Multi-Conductor Cables
Medical Grade Flat Wire

Medical Grade Insulated Round Wire
Teflon® PTFE Tubing
Uninsulated Wire

Wire Material

Silver Plated Copper
Bare Copper
Copper Based Alloys
Stainless Steel (304 and 316L)

Resistance Wire
Nickel Plated Copper
Specialty/Precious Metals on Toll

Insulation Material

Chemours Fluoropolymer Resin

  • Teflon® PTFE
  • FEP
  • PFA
  • Tefzel® ETFE
AWG

18 AWG to 50 AWG

Insulated Wire Diameter

Min – .010″

Max – .200″

Insulation Thickness

PTFE – Min – .0035″
FEP/PFA/ETFE – Min – .003″

Additional Capabilities

Flat Wire (Ferrous and Non-ferrous)
Drawing
Stranding
PTFE Extruded Strips
Braiding/Shield

Tape Wrapping
Etching
Cutting/Stripping/Tinning
Tubing / Teflon® PTFE Washers

Finished Wire Product Tolerance (+/-)

Outer diameter held to ±.001″ for insulated wire and for flat wire ±.0002″

Production Volume

Specialty Production Shop
Custom / Made to Order
Low Volume
Small Run

High Volume
Large Run
Long Run
Large Scale Production Volume Run

Typical Lead Time

3 to 4 weeks

Additional Information

Industry Focus

Aerospace
Military / Defense
Medical
Audio

Computer
Automotive
Electronics

Wire Form Products

Stranded
Braiding
Insulation

Industry Standards

ISO 9001:2015 Certified
International Organization for Standardization
Mil-Spec

Military Specifications

  • MIL-W-16878/6 (Type ET)
  • MIL-W-16878/4 (Type E)
  • MIL-W-16878/11 (Type K)
  • MIL-W-16878/13 (Type KT)
  • MIL-W-22759/12

NEMA HP3

File Format

PDF- Mostly 2D drawings