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Coated Aircraft Cable & Wire Rope

Extruding plastic coating onto wire rope and aircraft cable is a manufacturing process that we've performing and refining since our company's inception.  Subsequently coating wire rope and aircraft cable is one of our biggest value streams to this day.  Our in-house coating process is a jacketing application via pressurized extrusion.  We supply coated wire rope and aircraft cable on reels, in pre-cut lengths or fabricated into assemblies. The first plastic resin that we first began extruding is polyvinyl chloride aka PVC aka vinyl.  PVC remains as our highest volume coating.  The next highest volume coating that we extrude is nylon.  

PVC coating is used for general purpose applications.  The many reasons for PVC coating of wire rope include aesthetics, ergonomics, protection.and visibility.  It's used in a wide variety of environments such as indoors or outdoors, wet or dry, exposed or unexposed to UV light.  Typical transparent PVC colors that we coat include:
  • Clear
  • Translucent Red
  • Translucent Blue
  • Translucent Green
  • Translucent Purple
  • Translucent Smoke
Typical opaque (solid) PVC colors that we coat include:
  • Opaque Black
  • Opaque Blue
  • Opaque Red
  • Opaque Orange
  • Opaque Yellow
  • Opaque White
  • Opaque Forest Green
  • Opaque Olive Drab
  • Opaque Brown
​The highest visibility opaque (solid) PVC colors that we coat include:
  • Opaque Neon Pink
  • Opaque Neon Yellow
  • Opaque Neon Green
  • Opaque Flourescent Red

The main advantage of nylon coating in lieu of PVC center around it's endurance characteristics in high friction applications.  Ways you can observe the higher endurance to friction include the nylon's hardness and temperature rating.  Nylon protects the inner-cable from fraying.  Typical nylon applications include:
  • Cycling over pulleys and sheaves (fitness cables, conveyor cables, etc)
  • Push-push control actuation
There are two nylon product families that we coat: nylon-6 and nylon-11.  Nylon-6 is standard grade and the more economical nylon option.  Nylon-11 is the highest quality nylon option and it's slightly more flexible than nylon-6.  Nylon-11 is recommended for maximizing life cycles in the most demanding applications.  Nylon-11 is recommended for push-pull control applications.  For residential application of fitness cables nylon-6 is typically adequate.  For commercial gym application of fitness cables that see rigorous use, nylon-11 is recommended.

The nylon colors we typically coat include:
  • Translucent Clear
  • Translucent Green
  • Translucent Blue
  • Opaque Red
  • Opaque Yellow
  • Opaque Orange
  • Opaque Black
  • Opaque Pink

If one of our standard colors does not match your organization or product's color scheme close enough then we can quote based on coating your custom color.  Please provide a pantone number or hex number for the most accurate color match.

Nominal breaking strengths for plastic-coated wire rope and aircraft cable are based on the diameter and grade prior to coating.  It's recommended that the coating be stripped in order to swage metal on metal when forming load bearing terminations.  Crimping over coating results in light duty terminations and is not load rated.

MIL-DTL-83420 Type II = Jacketed Aircraft Cable per MIL-DTL-83420

Black powder coated cable is used for theatrical applications.  Since the coating is not plastic you can apply fittings directly to the cable to make load bearing connections when installed properly.

Plastic impregnated (spacelay) is used in the logging industry at saw mills.  The coating is applied in between the strands for added protection from abrasion.

Please let us know if you require RoHS or REACH compliant coated wire rope. 

We look forward to supplying with your coated wire rope or aircraft cable requirement.  Upon special request, we can supply coatings that you may not see above such as HDPE, Hytrel and FEP.


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Wire rope products are utilized in vastly diverse industries and environments. Our job at Lexco Cable is to guide our customers' decisions in selecting the optimal combination of wire rope products for their unique applications.