TPU spiral cables combine the memory of a coiled spring with the durability of thermoplastic polyurethane — producing a retractile cord that extends under load and returns to its compact rest length without fatiguing. Nexharn Connectivity manufactures custom TPU spiral cables for industrial handtools, portable medical devices, safety tethering systems, point-of-sale terminals, and any application where cable management and flex life are critical requirements.
Our spiral cables are wound on precision mandrels to a controlled pitch and helix diameter, then heat-set at calibrated temperatures that lock the coil memory. The result is a cable that reliably returns to its rest length after tens of thousands of extension cycles.
TPU vs PUR Spiral Cables
Two jacket materials dominate the spiral cable market. Understanding the difference helps specify the right cable for your environment:
| Property | TPU (Thermoplastic Polyurethane) | PUR (Polyurethane Rubber) |
|---|---|---|
| Abrasion resistance | Excellent | Good |
| Chemical resistance (oils, coolants) | Very Good | Excellent |
| Low-temperature flexibility | Good (–20 °C) | Excellent (–40 °C) |
| UV resistance | Good | Good |
| Hydrolysis resistance | Standard grade: moderate; Hydrolysis-resistant grade: excellent | Excellent |
| Coil memory retention | Excellent | Very Good |
| Typical temperature range | –20 °C to +80 °C | –40 °C to +90 °C |
| Cost relative | Standard | Premium (+15–25%) |
For most industrial handtool and barcode scanner applications, TPU provides the best balance of flex life, coil memory, and cost. For outdoor applications or environments with cutting fluid splash, hydrolysis-resistant TPU or PUR is recommended.
Specifications
| Parameter | Standard Range | Custom Options |
|---|---|---|
| Conductor count | 2 – 20 conductors | Up to 40 conductors |
| Conductor gauge | AWG 28 – AWG 18 | AWG 16 for power-carrying spiral cables |
| Conductor material | Fine-stranded tinned copper (flexible class 5) | Shielded pairs available |
| Jacket material | TPU (standard), PUR (on request) | Halogen-free, hydrolysis-resistant TPU |
| Jacket color | Black, grey, yellow, blue, red | RAL color match on request |
| Coil rest length | 0.5 m – 3 m | Custom rest length |
| Coil extended length | Up to 5× rest length | Up to 8× for lightweight cables |
| Outer diameter (coil) | 20 mm – 100 mm | Custom OD |
| End connectors | None, open ends, or customer-specified connector | M8, M12, RJ45, DB9, custom |
| IP rating (with connectors) | IP65 | IP67, IP68 on request |
| Flex life | 50,000 cycles minimum at rated bend radius | 500,000+ cycles with fine-stranded AWG 24–28 |
Applications
- Industrial handtools: Power tool cords, pneumatic tool leads, electric drill power cables
- Barcode and RFID scanners: Handheld scanner tethering cables for warehouse and retail POS
- Medical devices: Patient monitoring leads, handheld diagnostic device cables, cleanroom-compatible TPU jacketed harnesses
- Safety tethering: Tool lanyards, fall-arrest auxiliary cables, worker-to-equipment safety tethers
- Automotive diagnostics: OBD-II extension cables, diagnostic tool connectors
- Security and access control: Card reader extension cables, intercom handset cords
Certifications
- RoHS 3 compliant (Pb, Cd, Cr VI, Hg, PBDE, PBB-free)
- REACH SVHC declaration
- CE (LVD) for applicable voltage ratings
- UL/CSA AWM ratings available for conductor materials used
Frequently Asked Questions
What is the standard MOQ for TPU spiral cables?
MOQ is 200 pieces for standard configurations (no custom connector, 2–4 conductors, black jacket). Custom connector assemblies, non-standard colors, and shielded variants require a minimum of 500 pieces. Sample quantities of 5–10 pieces are available for first-article qualification.
How is flex life tested for TPU spiral cables?
We test flex life by extending the coil to full rated length and returning it to rest length continuously on a motorized flex tester. The pass criterion is that conductor resistance does not increase by more than 5% and no electrical open-circuit occurs during the rated cycle count. Standard spiral cables are rated to 50,000 cycles; premium fine-stranded variants are rated to 500,000 cycles.
Can Nexharn add custom connector types (M12, RJ45, USB-C)?
Yes. We overmould or field-terminate most standard connector types onto spiral cable ends: M8/M12 (A/B/D/X coding), RJ45, RJ11, DB9/DB15/DB25, USB-A, USB-B, and custom connector types with appropriate tooling. Overmoulded strain reliefs are standard on connector terminations.