High Flex Cable Assembly
Custom high-flex cable assemblies for robotics, cable tracks, and motion control. Rated for millions of flex cycles.
High Flex Types
Various high-flex cable configurations for different applications.
Motion Control Solutions
High-flex cables are essential for applications with continuous motion. We manufacture flex-rated assemblies for robotics, automation, machine tools, and cable track systems.
- Millions of flex cycles
- Cable track rated
- Robotic applications
- Torsion flex options
- Shielded flex cables
- Oil resistant jackets
- TPE/PUR insulation
- Flex life testing
Applications
Robotics
6-axis robots, cobots
Automation
Gantry, linear motion
Machine Tools
CNC, machining centers
Packaging
Pick and place, conveyors
High Flex Cable Assembly for Continuous Motion Applications
As a specialized high flex cable assembly manufacturer, OurPCB delivers continuous-flexing cables rated for 10+ million flex cycles. Our cable assembly expertise covers cable track (energy chain) cables, robotic arm harnesses, and torsion-flex assemblies for demanding motion control applications.
High-flex cables use fine-stranded conductors and special insulation materials (TPE, PUR) that distribute bending stress to prevent conductor fatigue. Cable track-rated assemblies handle the repeated bending of energy chains in gantry systems, while robotic cables handle 6-axis motion with torsion requirements.
Our shielded high-flex cables combine EMI protection with continuous flexing capability. Oil-resistant PUR jackets suit machine tool applications where coolant exposure is common. We also provide multi-conductor flex cables for complex automation systems.
Applications include industrial automation with linear motion systems, CNC machine tools with moving axes, packaging machinery with pick-and-place motion, and semiconductor equipment with clean-room requirements.
We use connectors from Molex, TE Connectivity, and Hirose designed for flex applications. Rapid prototyping validates flex life before production. Contact us for high-flex cable assembly quotes.
From the Case Bank
An Australian mining equipment integrator sought a supplier for custom low-to-moderate volume wiring harnesses, with projected significant volume scaling over a three-year horizon.
The client needed a supplier capable of handling initial low-volume prototype runs while supporting a rapid scale-up to high volumes, all while competing against their existing vendor base.
Provided a competitive quotation for the initial low-volume order with a 4-week lead time, demonstrating manufacturing flexibility for low-volume starts and outlining capacity planning for future volume scaling.
Successfully entered the vendor evaluation shortlist, with the client initiating parallel inquiries for additional projects and planning a factory audit to finalize the long-term partnership.
- 20 sets initial order
- 4-week lead time
- Forecast: 50 sets in 2026
- Forecast: 500 sets in 2027
- Forecast: 1000 sets in 2027
High Flex FAQ
High-flex cables use stranded conductors with very fine strands, special insulation materials (TPE, PUR), and construction designed to distribute bending stress. These features allow millions of flex cycles without failure.
Flex life depends on bend radius, speed, and cable construction. Premium continuous-flex cables rated for 10+ million cycles are available for demanding robotics applications. We specify cables appropriate for your cycle requirements.
Yes, we manufacture cables specifically designed for cable track (energy chain) applications. These cables handle the repeated bending and are available with shielding, multiple conductors, and various jacket materials.
Need High Flex Assemblies?
Continuous flexing cables for robotics, automation, and motion control applications.