Custom Flat Cable Services | Engineering Flat Cable Solutions
Looking for a professional Custom Flat Cable manufacturer? We provide one-stop custom flat cable service from design to delivery. Suitable for all kinds of projects such as automation, robotics, medical, rail transportation and so on.
Why Choose Custom Flat Cable Services?
In many industrial, medical, robotic and other highly integrated systems, standard cables often fail to meet the needs of space constraints, functional composites, wiring efficiency and other aspects. Flat Cable, on the other hand, has gradually become the preferred solution in engineering design due to its compact structure, good flexibility and simple wiring.
However, you will find that the standard flat cables on the market are limited in variety, fixed in arrangement, and not flexible enough in function. At this point, custom flat cable becomes especially important.
- Custom Flat Cable to fit your space structure.
- Integrating signal and power.
- Custom flat cables to fit your assembly process.
- Improve system stability and immunity to interference.
- Meet branding, certification, and material orientation requirements
- Achieve better aesthetics and brand perception.
What Custom Flat Cable services can we provide?
As an experienced cable manufacturer, Linkwings offers complete flat cable customization services. From design optimization and material selection, to mass production and export packaging, we are able to work together in one stop.
Whether you are making a medical trolley, robotic system, automated drag chain equipment, or rail transportation, or consumer electronics, we can customize it according to your requirements.
| Customizable Item | Available Options / Description |
|---|---|
| Conductor Type | Tinned copper, bare copper, stranded wire, alloy wire |
| Wire Count | From 2 cores up to 60+ cores |
| Layout Style | Parallel, staggered, double row, side branch available |
| Wire Gauge | 30AWG ~ 12AWG or as requested |
| Insulation Material | PVC, FEP, SR-PVC, PE, TPE (RoHS/REACH compliant) |
| Shielding Structure | Aluminum foil, braid shield, double shielding |
| Jacket Color | Black, grey, white, blue, transparent or custom color |
| Connector Assembly | Soldering, crimping, terminal pressing, overmolding |
| Labeling / Marking | Silkscreen, heat transfer, UV code, QR, serial marking |
| Cutting & Packaging | Pre-cut length, reel supply, ESD bag, moisture-proof |
We can also offer you:
- Free preliminary structural evaluation and selection advice
- Assist customers to draw wiring diagrams or drawings conversion (DWG, PDF, 3D format)
- Sample proofing support: 5~15 days delivery
- Global export services, support for Europe, America/Middle East/Southeast Asia markets
- Third-party testing (RoHS, REACH, voltage test, shielding performance test) cooperation
Considerations for Custom Flat Cable
At Linkwings, we support multi-dimensional customization of flat cables from material construction to functional configuration. Ensure that the cable is perfectly adapted to your equipment architecture and system requirements.
Number of wires and layout
We support the customization of the number of cores from 2 cores to more than 60 cores. And according to the use of space and functional partition requirements, flexible arrangement of wire core. Common layout methods include side-by-side, staggered, multi-row, zoned wiring, and even single-ended or double-ended branching, adapting to complex structures and highly integrated equipment wiring needs.
Conductor Type and Gauge
Conductors are available in tinned copper, bare copper or alloy. The wire gauge ranges from 30AWG to 12AWG, which is suitable for all kinds of signal, control and power cables. We also support the design of mixing thick and thin rows to ensure performance matching, compact structure and electrical safety.
Insulation and Sheath Types
We offer a wide range of insulation and sheath materials, such as PVC, SR-PVC, FEP, TPE and so on. We can meet the requirements of flexibility, temperature resistance, flame retardant and cleanliness in different scenarios. Meanwhile, we support single-layer or double-layer sheath structure, and can also customize brand-specific colors or transparent sheaths to enhance product consistency and recognition.
Shielding structure
According to the anti-interference requirements, the cable can be added with aluminum foil shielding, braided shielding or double-layer composite shielding, which effectively reduces the impact of EMI and guarantees communication stability. The shielding structure is especially suitable for robotics, medical, electric vehicles and other scenes with high signal integrity requirements.
Plug and Terminal Processing
We can provide terminal crimping, welding, molded plugs and other connection processing services according to customer needs. We support TE, Molex, JST and other brand interfaces, and can also customize the development of non-standard connectors. We can help customers realize the “plug and play” assembly effect, eliminating the need for secondary processes.
Length and Cutting Method
We support customized cutting to any length with an accuracy of ±2mm, and offer a variety of shipping methods such as bundles, reels, and anti-static packaging. The cables can be pre-cut or sequenced for shipment, which is suitable for assembly line assembly or standardized operation process.
Interested in Custom Flat Cable Solutions?
Contact our team of experts to learn more about tubing our wide range of customized flat cable features.
Application for custom flat cable
Flat Cable is a great customized solution in high-end equipment and space-constrained systems. Flat Cable is highly flexible, compact, easy to route, and supports multi-core integration. Compared with traditional round cables, Custom Flat Cable is more suitable for industries that require multiple wires in a row, frequent movement, and extreme space utilization.
Automation Equipment & Drag Chain Systems
In industrial automation equipment, CNC machines, slide systems, cables often move with the arm or drag chain.Flat Cable advantages are as follows:
- Can be embedded in the drag chain use, bending life of up to a million times or more
- Neatly arranged core wires, consistent tension, improve reliability
- Multi-core side-by-side for significant space savings in the raceway
Intelligent Robot & Robotic Arm Control System
In the joint area, robots require frequent dynamic movements. Cables need to be flexible, lightweight and minimize interference at the same time, and Flat Cable delivers:
- Ultra-thin design, suitable for robotic arm joint space
- Supports mixed signal + power cables to minimize wiring.
- Optional shielding layer to reduce servo signal interference
Medical Equipment & Medical Carts
Medical devices demand the highest levels of cleanliness, safety, flexibility and dimensional control from their cables. Flat Cable can provide both of these requirements, which are difficult to meet with standard cables:
- Support for small, high-density designs to fit into tight spaces inside instruments
- Customizable white or clear jacketing for aesthetics and ease of cleaning
- Multi-functional cables (control + signal + power) in one package
Rail and Elevator Systems
Door opening and closing systems, elevator follow systems require cables that can follow the frequent movement of the equipment and where space is at a premium. Advantages of using Flat Cable:
- Multi-wire integration and easy branching design for door interlocking systems.
- Customizable fireproof, abrasion-resistant and vibration-resistant material
- Finished product is neat and uniform, easy to install and test
New Energy Vehicle & Battery Pack Connection
New energy vehicle battery packs, charging modules, on-board control units, wiring requirements for high reliability, thin and light, anti-interference.Flat Cable Advantage:
- Sensor cable, power cable and control cable can be integrated into one.
- Compact layout, strong EMI resistance
- Can be used for BMS module connection, battery individual voltage sampling cable
Consumer Electronics & Print/Display Modules
Compact, multi-core devices such as printers, scanners, LED control modules, and other space-conscious connections.Flat Cable Advantage:
- Easy to cut, easy to thread, can be matched with connectors.
- Optional ultra-thin/transparent cables, aesthetic appearance
- Supports stable transmission of low-voltage signals
Working With a Custom Flat Cable Manufacturer
Working with a professional Custom Flat Cable manufacturer is more than just placing an order, it’s a collaborative process that involves deep engagement. From the number of cores, conductor construction and insulation materials, to the layout, shielding and even the installation of connectors, every detail is closely related to the performance of the equipment and the efficiency of the assembly. A qualified supplier should be able to help you identify potential problems and propose better solutions before you ask for them.
At Linkwings, we understand the pace and reality of project constraints. Our experienced technical team can assist you in designing cable structures from scratch, or optimizing the layout, electrical parameters and material selection based on existing drawings. We are willing to accompany you in your project with an engineer’s mindset, rather than just providing a finished product. Instead of “standard products”, we can customize the best connection solution for your equipment in one step.
Why Choose Linkwings as Your Custom Flat Cable Manufacturer
As a manufacturer specializing in engineered custom flat cables, Linkwings serves customers from industrial automation, robotics, medical devices, new energy, rail systems and more. We are not only a manufacturer, but also a co-designer and facilitator of your engineered connectivity solutions.
- Engineering team that understands you: We are not simply a “wire processing” team, but an engineering team with experience in structural engineering, electrical connections, material selection and other areas. Even if you don’t have drawings, we can assist you in developing a feasible wiring plan from the application scenario.
- Rapid prototyping & small batch support: We understand that “time and flexibility are more important than anything else” in the early stages of a project. Support from as little as 100 meters, ready for R&D, small batch production.
- Customizable: From wire construction and core count, to insulation, shielding, and plug processing, we can customize and optimize for your actual equipment needs.
- Experienced in export: Linkwings has exported to more than 20 countries and regions, including Europe, America, Japan, Korea, Southeast Asia, and the Middle East, and has rich experience in the export process and preparation of documents.
- Customer-oriented service philosophy: At Linkwings, you are our partner in developing and solving problems side by side. We are willing to support you from the early stage of the project, and handle the “small matter” of cable in a professional, hassle-free and reliable way.