Teflon Zip Wires Terminated - QL- Custom.com | Custom Over molding Cable Wire Harness Manufacturer

What's the Teflon flat ribbon wire

It's a teflon coated ribbon wire, high temperature coated like PTFE,FEP,PFA ETFE wires

The flat, tape-like shape of Teflon flat ribbon wires hides a number of conductors. Teflon Zip Wires Terminated insulation, such as PTFE, FEP, PFA, or ETFE, surrounds each conductor. The cable is sleek and slim, so it takes up a lot less space than the round one. These teflon wire assemblies are a long-lasting way to keep high-end devices safe instead of nylon ties. Most of the time, each flat wire is soldered or connected to a connector so that it can be plugged in and used right away. People often call them PTFE wire or Teflon wire because the Teflon (PTFE) coating on the wire protects it from heat and chemicals. These ribbon cables are the best choice when accuracy and reliability are the most important things.

teflon zip wire rated temperature

PTFE and PFA can rate 250℃ FEP and ETFE can rate 200℃

Teflon Zip Wires Terminated won't break, even when it's really hot. PTFE (Teflon) or PFA insulated cables work well at temperatures up to about 200-250°C. These materials can handle even higher spikes, up to about 260°C, for short periods of time. In practice, the continuous use rating for PTFE wires is 200 °C. FEP and ETFE insulated ribbons can handle temperatures of up to 150-200°C. These grades are better than regular PVC wiring. High-temperature zip ties made of Teflon may be able to carry electricity near ovens or engines without melting. Even at these very high temperatures, the insulator and the copper core still conduct electricity. Our assemblies are unbreakable when it comes to long-term heating or quick bursts of heat because we only use materials that have been tested for these levels.

Teflon coated wire advantage

Heat resistant

Teflon materials are very good at withstanding high temperatures. Teflon Zip Wires Terminated, on the other hand, keep their properties even when they are heated to very high temperatures. Because they stay flexible and strong up to 200°C, when nylon would break, they are excellent heat-resistant zip ties. The cables don't change shape because they have high glass transition temperatures. When these Teflon Zip Wires Terminated are used, bundles will stay together even when they are in hot places like furnace zones or when they are working near engines. This keeps signals steady, no matter what happens in the environment, which protects devices.

Resistente agli agenti chimici

Fluoropolymer cables are known for their ability to resist chemical corrosion. PTFE (Teflon) coatings don't let fuels, acids, solvents, oils, or gases through. This wire is great for labs, oil rigs, and businesses that work with strong chemicals because it can handle cable ties and is resistant to chemicals. For example, a Teflon bundle will stay together even when it is soaked in strong acids, cleaning solvents, or gasoline. Because of this lack of movement, there are no shorts or failures in the insulation. In short, Teflon Zip Wires Terminated can't be damaged by the kinds of liquids that would normally damage regular cables.

Zip wire can save more space

Flat ribbon (zip) cables take up a lot less space than round wires. Flat wires take up about half as much space as similar round bundles. They stick to surfaces and fit into tight spaces by running conductors next to each other. When you put zip tie wires (flat bundles) in a panel, you can route the walls of the chassis better. They don't have to deal with the heavy filler materials that round cables need. In practice, using flat Teflon Zip Wire Terminated makes the amount of wiring much smaller. This is very helpful for aerospace and portable equipment because it cuts down on the area of the panels and can also cut down on the weight of the whole system.

Teflon coated wire materials

Teflon zip cables are a mix of strong conductors and high-tech insulators. We use conductors that are made of very pure copper and have metals on them that stop corrosion. Teflon is a name for coatings made of fluoropolymer polymers like PTFE, FEP, or PFA. These coatings are very resistant to heat and chemicals. The way each layer is tightly bonded together makes a perfect surface.

Nickel plated copper

Nickel-plated copper is usually what carries the electricity in our Teflon Zip Wires Terminated. In this way, a very thin layer of nickel is put on each copper thread. Nickel plating is better at resisting corrosion and high temperatures than other types of plating. It stops copper from oxidizing at 200°C and makes it easier to solder. Nickel-plated copper also has a very high conductivity. The nickel coating protects the wires from wear and tear caused by bending and vibration. This is why nickel-copper is often used in wiring harnesses for cars and planes. Because of the nickel finish, you can be sure that your Teflon zip wire bundles will stay conductive and not rust.

Teflon coated insulation plastic resin

We use fluoropolymer resins to insulate. PTFE (Teflon), PFA, FEP, and ETFE are some examples of these polymers. Both can handle heat and chemicals well. PFA and FEP can be melted and processed, but PTFE is reactive and can handle very higher temperatures. ETFE (Tefzel) is also a popular choice because it lasts a long time. These fluoropolymer cable materials are great because they are flame-resistant and have a low dielectric loss. Even when exposed to high temperatures, insulation stays flexible and doesn't catch fire. This makes sure that the zip wire is safe and stable.

PTFE advantage

PTFE is by far the most common type of Teflon used to insulate wires. Some of its most important features are that it is very chemically inert and can handle very high temperatures (up to 260°C). Because it is slippery and has low friction, PTFE can handle millions of flex cycles without getting damaged. Its high dielectric strength makes interference and crosstalk even less likely. PTFE cable has a higher voltage rating, can handle higher temperatures, and is more resistant to chemicals than PVC or nylon. These are just a few of the benefits. Because of these and other reasons, PTFE wire is known as the "King of Plastics" in the electronics industry.

Teflon coated wire solutions

We provide complete Teflon zip wire harness solutions, including design, extrusion, assembly, and testing. Our service covers connectors and terminations, and we can integrate zip wire with other cables or combine multiple ribbons into one harness. We produce molded plugs and custom pinouts in-house, ensuring each assembly meets your exact specifications. Together, we can optimize the layout for your project.

Cable extrusion

Cable extrusion is the process of making the Teflon insulation that goes around the conductors. We melt and extrude raw PTFE (or FEP, PFA, etc.) pellets as part of our production process. The Teflon coats the flat conductor core evenly as it gets hotter. You can get each conductor layer to be the same and smooth by carefully controlling the temperature, pressure, and pull speed. After extrusion, the cable is cooled and drawn to get the exact thickness. Using this technology to make wire that can handle high temperatures is quick and easy. There are no seams or gaps in the Teflon sheath because it is made from a single piece during extrusion. This makes it last longer.

Zip wire section analyze

After we make each flat cable piece, we check its quality. We check the cross-sectional measurements and make sure they match the specs. After that, each conductor is tested for electrical problems. After each assembly is done, a full circuit continuity test is done. We also make sure that the crimps and terminations meet IPC standards by doing pull and tension tests. Every part or branch of a cable is recorded and named. We also look at how the inside layers of layered or multi-zone wires are lined up. You can also test the coating on cables with plated conductors, like nickel-copper-nickel-copper. We check each part of the cable for visual, dimensional, and electrical problems.

How to identify the wire pin number after zipped

After multiple wires are zipped or bundled together, clear identification is crucial. We offer color-coding and marking options. One method is color-striping: thin colored filaments or tracers can be embedded in the insulation of each conductor. These stripes correspond to pin numbers or wire functions. For very complex harnesses, multiple-colored lines can be mixed (for example, white with a red stripe), allowing dozens of unique codes. Another method is over-jacket printing. We print text, numbers, or logos directly on the flat cable. This might include the pin sequence, overall part number, or reference information. After finishing, each end of the cable can also be labeled or tagged with the wire numbers. Together, these methods make it easy to trace any conductor from one termination to the next.

Industrie e applicazioni

Automotive & Transportation

Cars and trains use these cables in engines and batteries. Our automotive high-temp ties and flat wires are found under hoods and in exhaust controls. They handle engine bay heat and road grime. In high-speed trains and EVs, these zip cords keep complex sensor bundles neat and safe.

Aerospace & Aviation

In aircraft and spacecraft, wiring must withstand heat and vibration. Our aviation cable ties, harnesses, and high-temperature zip ties secure avionics in tight panels. The flameproof PTFE insulation is ideal near engines and turbines. These Teflon zip wires are also used in satellites and drones.

Industrial & Manufacturing

Factories, robots, and power plants require robust wiring. Industrial zip ties, high-temp harnesses, bundle cables in ovens, presses, and motors. Their chemical resistance makes them perfect for metal plating or pesticide sprayers. In automated lines, flat Teflon cables provide reliable flexing without damage.

Oil, Gas & Chemical Processing

Refineries, rigs, and pipelines use chemical-resistant cable ties for pump and valve controls. Our Teflon zip wires stand up to gasoline, crude oil, acids, and high pressure. For subsea or refinery instruments, fluoropolymer insulation ensures long-term reliability in harsh, oily, corrosive environments.

Medical & Pharmaceutical

Clean and inert wiring is a must in hospitals and labs. Our medical cable ties high-temp devices are used in MRI machines, ventilators, and X-ray equipment where heat and radiation are present. The flat ribbon form also suits medical gear that must be compact and sterile.

Electronics & Semiconductors

Precision electronics assembly and chipmaking need pure, stable wires. Teflon zip cables route signals in test equipment and fabrication machines. PTFE’s low electrical noise preserves signal integrity. These cables are often used in clean rooms and high-vacuum systems, matching stringent industry demands.

Commercial Value & Supply Advantage

Faster Setup with Ready-to-Use Teflon Zip Wires

The flat cables are already in place. Don't cut any wires, or else you'll have to strip or crimp them. Each zip wire already has connectors or tabs on it. We can save time and avoid mistakes by doing this. You can put the cable right into the machine. This timesaver could cut the time it takes to build in half, from days to hours.

Low-Cost Wiring That Still Performs Well

We make our Teflon flat cables in large batches so that we can keep prices low. Flat cables are usually cheaper than round ones because they need less material to make. We cut the wires to the right length so we don't waste any. These cables save space and weight, which lowers shipping and assembly costs. They are cheaper and less likely to break when exposed to heat and chemicals than regular PVC wires.

A Reliable Source for Zip Wire Supply

Our customers rely on us for strong manufacturing and dependable partners around the world. Our ISO9001:2015-certified facility can help you increase production and meet deadlines. More than 300 of our clients in Europe and North America are happy with our work. We help you get resources, prices, and delivery schedules through contract manufacturing, which makes us a reliable long-term supplier.

Manufacturing & Customization Capabilities

Customized Sections

Different projects have different needs. We make each cable to fit the exact needs of your job. You can choose the type of insulation, the size of the wire, and the length of the wire. We carefully cut the flat cable so that the results are neat. Our experts can add any connector you need, from standard pin headers to unique plugs. There are options for cable width, pin spacing, molded boots, and shielding, among other things. We will use either your drawings or ours.

From Small Samples to Large Production Runs

We are happy to help with both small and large orders. You can try out your design before you buy it with our fast quotes and samples. Once everything is approved, we use our automated cutting, crimping, and molding machines to make more of them. We can promise that every order, from the first sample to the last, will be of the highest quality if we keep everything in-house.

Connector Styles

We have a connection style that will work with your cable, no matter what you need it for. Some types of these connections are crimped contacts, wire-to-wire connections, soldered pins, and molded connectors. Our seals, strain reliefs, and protective parts are made to last even in tough situations. You could label each cable to make it easier to find. If you choose the right connection style, the cable works perfectly.

Quality Control & Compliance

Our factory follows the quality standards set by ISO 9001:2015. Two of the raw materials, wire and Teflon resin, have certifications that show they meet RoHS and other standards. We check each harness for full circuit continuity and pull force while we install it. IPC/WHMA-A-620 standards say that every connection crimp makes sure that the termination is reliable. We may also do flash tests and insulating resistance tests if we need to. The last thing to do when checking finished cables is to look at their size and markings. We can show that our products are safe according to UL and CE rules if we have the right paperwork (RoHS, REACH, UL). We take care of all of these compliance inspections for businesses that have to do them, like healthcare and transportation. You can be sure that every Teflon zip wire harness is of the best quality because they are all carefully checked, labeled, and certified before they are sent to you.

Recensioni dei clienti

These Teflon zip wires terminated were exactly what our aerospace project needed. The flat, high-temp cable bundles fit our engine compartment perfectly and survived the heat without issue. Assembly was plug-and-play and error-free.

James Reynolds

We ordered custom PTFE insulated ribbon cables with connectors. QL-Custom’s team guided us on color coding and pinout. The cables arrived fast and worked perfectly in our medical device, which runs hot. Highly recommended.

Linda Chen

Our robotics lab uses these flat fluoropolymer cable assemblies for multi-sensor rigs. They saved us a ton of space and assembly time. The chemical resistance is amazing — they handle every solvent we throw at them.

Sarah Patel

Excellent service from QL-Custom. They made us a batch of overmolded PTFE ribbon cables quickly and the quality is top-notch. The cables are very clean and consistent — no defects at all.

Robert Kim

We needed heat-resistant zip wire parts for our aerospace control unit. QL-Custom delivered spot-on specs and outstanding quality. The wires stay stable at 250°C and the nickel-plated conductors make them look very well-built.

David Johnson

Great customized Teflon Zip Wires Terminated solution. The flat cable with individualized pin numbers printed on the jacket made troubleshooting easy. Even in our cleanroom, the Teflon insulated wires held up.

Anna Müller

Most Reliable Partner for Teflon Zip Wires Terminated

When you need Teflon Zip Wires Terminated, your first choice should be QL-Custom Technology Ltd. We have been putting together high-temperature cables for decades and are ISO9001 certified. More than 312 businesses in Europe and North America trust our products. Because our engineering team is so good at working with you to come up with a custom solution, you could have a price from our factory and a prototype in your hands in just a few days. We do a lot of testing and keep our IPC certification to make sure that every harness is up to par. In short, our reliable service is backed up by our extensive knowledge of PTFE Teflon wire. For all of your high-quality Teflon wire needs, trust QL-Custom.

Fili in teflon terminati