High-Flex Wire Harness
High-flex cables and wire harnesses engineered for millions of flex cycles. Perfect for robotics, automation, and any application requiring continuous motion.
High-Flex Applications
Continuous flex solutions for demanding motion applications.
Robotic Arms
6-axis industrial robots requiring continuous motion cables
Cable Carriers
Energy chain and drag chain applications
Linear Motion
Gantry systems, pick-and-place machines
Torsion Applications
360° rotation and twisting requirements
Machine Tools
CNC machines, moving heads, turrets
Automation Systems
Assembly lines, conveyor systems
Engineered for Endurance
Our high-flex cables feature specially engineered construction for continuous motion applications. Fine-strand conductors, optimized lay lengths, and flexible jacket materials work together to deliver exceptional flex life without signal degradation or mechanical failure.
- Fine strand conductors (class 5/6)
- Rope lay stranding for flexibility
- PUR/TPE flexible jackets
- Oil and chemical resistant options
- EMI shielding available
- Energy chain compatible designs
- Torsion-resistant constructions
- UL/CE certified options
Technical Specifications
Our high-flex wire harness capabilities.
What Makes Our Cables Flexible
The key to high flex life is in the details of cable construction. Every element is optimized for continuous motion.
Premium High-Flex Wire Harness Manufacturing for Continuous Motion Applications
As a specialized high-flex wire harness manufacturer, OurPCB engineers and produces continuous flex cable assemblies rated for millions of flex cycles. Our wire harness solutions are designed for robotics, automation, and industrial motion applications where cable failure means production downtime.
Our continuous flex cable assemblies feature fine-strand conductors (Class 5/6), rope-lay stranding patterns, and flexible PUR or TPE jackets engineered for exceptional flex life. Whether you need cables for 6-axis robotic arms, industrial automation equipment, or energy chain applications, we deliver harnesses that withstand 5 million to 30+ million flex cycles.
Our high-flex cable assemblies achieve minimum bend radii as tight as 5x the outer diameter, enabling compact machine designs without sacrificing cable life. We offer shielded options for applications requiring EMI protection during continuous motion, including encoder feedback cables and servo motor connections.
For torsion applications like robotic arm cables, we provide specialized constructions rated for ±360°/m continuous rotation. Our cables are designed for cable carrier (energy chain) compatibility with appropriate outer diameters and jacket materials. We work with leading cable carrier brands including igus, Kabelschlepp, and Tsubaki to ensure compatibility.
Our engineering team helps you select the optimal high-flex cable construction based on your motion profile, travel speed, acceleration, and environmental conditions. With 48-hour prototyping capabilities, you can test cable performance before committing to production. We offer no minimum order quantities, supporting projects from single prototypes to volume manufacturing. Contact us to discuss your custom high-flex wire harness requirements.
High-Flex Cable FAQ
Our high-flex cables are rated from 5 million to over 30 million flex cycles depending on the application requirements and cable construction. The actual flex life depends on factors including bend radius, travel speed, acceleration, and environmental conditions. We can recommend appropriate constructions based on your specific motion profile.
Our high-flex cables achieve minimum bend radius as tight as 5x the outer diameter for the most flexible constructions. Standard high-flex cables typically have 7.5x to 10x bend radius. We work with you to select the right construction based on your space constraints and motion requirements.
Yes, we design cables specifically for cable carrier (energy chain) applications. These cables feature appropriate outer diameter, surface finish, and flexibility for reliable performance in drag chain installations. We can match cables to your specific cable carrier brand and size requirements.
Yes, we manufacture cables designed for torsion applications including robotic arm cables that need to handle continuous rotation. These cables feature special conductor stranding patterns and jacket designs that resist the fatigue associated with twisting motion.
Need High-Flex Cables?
From single prototypes to production volumes, we deliver high-flex cable solutions engineered for your specific motion requirements.