ETFE power cables are designed for high-performance electrical applications where temperature resistance, mechanical strength, and chemical durability are critical.
ETFE, short for Ethylene Tetrafluoroethylene, is a fluoropolymer insulation material known for its excellent dielectric properties and lightweight toughness, making it ideal for aerospace, defense, industrial, and automotive power systems.
ETFE Power Cables
If you need cables that withstand high heat, radiation, and harsh chemicals without compromising performance, ETFE insulated cables are the perfect choice.
What Is an ETFE Power Cable?
An ETFE power cable is an electrical cable that uses ETFE as insulation or jacket material to protect the conductor.
Compared to conventional PVC or XLPE cables, ETFE cables deliver superior electrical stability, temperature endurance, and mechanical strength in a much lighter form factor.
Typical Construction
Conductor: Tinned copper, silver-plated copper, or nickel-plated copper
Insulation: ETFE (Ethylene Tetrafluoroethylene) fluoropolymer
Shielding (optional): Braided tinned copper or aluminum foil
Jacket (optional): ETFE or cross-linked fluoropolymer
Key Features and Advantages
ETFE insulated power cables are engineered for reliability under demanding conditions:
⚡ High Dielectric Strength: Maintains insulation integrity up to 600V or higher
🔥 Temperature Resistance: Operates from –90°C to +150°C, with short-term peaks up to +200°C
🧪 Chemical Resistance: Withstands oils, fuels, solvents, and corrosive gases
💪 Mechanical Durability: Exceptional tensile strength, cut-through, and abrasion resistance
🧯 Flame Retardant & Low Smoke: UL 94 V-0 rated and halogen-free
📡 Stable Electrical Performance: Low dielectric constant ensures minimal signal loss
🛰 Lightweight Design: Ideal for aerospace and portable applications
Applications of ETFE Power Cables
ETFE cables are widely used in sectors that require lightweight, rugged, and heat-resistant power solutions.
✈️ Aerospace & Defense: Wiring for aircraft, satellites, and avionics systems
🚀 Space Applications: Power distribution in spacecraft and launch vehicles
🚗 Automotive: High-performance wiring in EVs and hybrid vehicles
⚙️ Industrial Automation: Motors, robotics, and control systems in harsh environments
🧬 Medical Equipment: Sterilizable and biocompatible wiring for critical instruments
⚡ Nuclear & Energy Systems: Radiation-resistant wiring in reactors and power plants
Technical Specifications
| Property | Typical Value |
|---|---|
| Conductor Material | Silver-plated or tinned copper |
| Insulation Material | ETFE fluoropolymer |
| Voltage Rating | 300V – 1000V |
| Temperature Range | –90°C to +150°C (up to +200°C short-term) |
| Dielectric Constant | ~2.6 |
| Flame Rating | UL 94 V-0 |
| Chemical Resistance | Excellent |
| Radiation Resistance | Up to 10⁶ rads |
| Weight | 30–40% lighter than PTFE cables |
ETFE vs PTFE vs FEP Cables
| Property | ETFE | PTFE | FEP |
|---|---|---|---|
| Temperature Limit | +150°C | +260°C | +200°C |
| Flexibility | Moderate | Medium | High |
| Abrasion Resistance | Excellent | Good | Moderate |
| Chemical Resistance | Excellent | Excellent | Excellent |
| Radiation Resistance | Excellent | Moderate | Good |
| Weight | Lightest | Heavier | Light |
| Cost | Moderate | Higher | Lower |
Summary:
ETFE cables provide the best balance between mechanical durability, temperature endurance, and weight savings—making them ideal for aerospace and industrial applications.
Why Choose ETFE Power Cables?
Choosing ETFE-insulated power cables means investing in reliability that lasts.
Their combination of thermal endurance, mechanical strength, and chemical stability ensures long-term performance in the most demanding conditions — far beyond what standard insulation materials can deliver.
TOT Wire & Cable supplies high-quality ETFE power and control cables, available in custom sizes, shielding options, and voltage ratings to meet your project’s specific requirements.
Conclusion
ETFE power cables are the go-to choice for industries that demand lightweight, durable, and high-temperature-resistant electrical systems.
Whether for aircraft, satellites, or industrial robotics, these cables provide consistent performance and safety under extreme conditions.
👉 Contact TOT Wire & Cable today to request a quote or discuss your requirements for ETFE power cables tailored to your application.
