Precision-Engineered Flat Wrap Cable Casing for Demanding Applications
Customized steel-reinforced cable casing engineered for reliable control cable protection, smooth movement and application-specific performance.
Flat Wrap Cable Outer Casing
Keli manufactures customized flat wrap cable outer casings that are available in two main types: spiral outer casing and twin-wire outer casing, with an extruded plastic liner that may be optionally incorporated inside the conduit, depending on application requirements. Available in multiple dimensions and material configurations, they are engineered for control cable routing in automotive, aerospace, medical, semiconductor and industrial applications.
Flat Wrap Cable Outer Casing Technical Parameters
| Specification | Liner Material | Steel Specification | Flattened wire thickness | Coating Material | OD Tolerance | ID |
| φ4 | PE\POM\PTFE\PA\PBT | 0.8-1.0 | 0.48-0.55 | PVC\PP\PA6\PE\TPE\TPEE | ±0.05 | 1.4-1.8 |
| φ5 | PE\POM\PTFE\PA\PBT | 1.05-1.3 | 0.5-0.7 | PVC\PP\PA6\PE\TPE\TPEE | ±0.05 | 1.7-2.0 |
| φ6 | PE\POM\PTFE\PA\PBT | 1.4 | 0.7 | PVC\PP\PA6\PE\TPE\TPEE | ±0.05 | 2.1-3.0 |
| φ7 | PE\POM\PTFE\PA\PBT | 1.6-1.8 | 0.85-1.0 | PVC\PP\PA6\PE\TPE\TPEE | ±0.05 | 3.0-4.0 |
| φ8 | PE\POM\PTFE\PA\PBT | 1.8-2.0 | 1.0-1.25 | PVC\PP\PA6\PE\TPE\TPEE | ±0.05 | 3.3-5.0 |
| φ9 | PE\POM\PTFE\PA\PBT | 2.0-2.1 | 1.1 | PVC\PP\PA6\PE\TPE\TPEE | ±0.075 | 4.0-5.0 |
| φ10 | PE\POM\PTFE\PA\PBT | 2.0-2.2 | 1.25 | PVC\PP\PA6\PE\TPE\TPEE | ±0.075 | 4.0-6.0 |
| φ11 | PE\POM\PTFE\PA\PBT | 2.2-2.4 | 1.1-1.8 | PVC\PP\PA6\PE\TPE\TPEE | ±0.075 | 4.0-6.0 |
| φ12 | PE\POM\PTFE\PA\PBT | 2.2-2.4 | 1.1-1.8 | PVC\PP\PA6\PE\TPE\TPEE | ±0.075 | 4.0-6.0 |
What Is Flat Wrap Cable Outer Casing and How Does It Work?
Flat wrap cable outer casing is built around a wrapped flat-steel-wire structure that forms a continuous path around an internal control cable. The construction provides a defined route for the cable while allowing the casing to follow bends during installation and operation.
The casing typically consists of three functional layers:
- Steel reinforcement: Forms the main structural framework and helps maintain the casing shape.
- Inner liner: Creates the cable-contact surface and can support smooth cable movement.
- Outer coating: Covers the reinforced structure and provides an additional protective layer.
During operation, the steel structure supports the casing, while the inner liner allows the cable to move within the casing with controlled friction. The outer layer helps isolate the assembly from the surrounding environment.
This layered construction makes flat wrap casing suitable for cable systems where controlled routing, mechanical support and reliable cable movement are required.
Construction & Material Options for Flat Wrap Cable Outer Casing
Flat wrap cable outer casing can be configured with different reinforcement, liner and coating options to meet specific cable system requirements. The main construction consists of a steel reinforcement, optional inner liner and outer coating.
Steel Reinforcement
The flat steel wire forms the core structure of the casing. Wire specifications can be selected according to the required casing dimensions, stiffness and mechanical requirements.
Inner Liner
The liner forms the internal surface around the cable. Different materials can be selected based on friction, wear and operating conditions.
| Material | Key Characteristics |
| PE | Low friction and economical |
| POM | Low friction and good dimensional stability |
| PTFE | Very low friction and chemical resistance |
| PA | Good strength and wear resistance |
| PBT | Good thermal and dimensional stability |
Outer Coating
The outer coating protects the reinforced structure and can be selected according to the required flexibility, abrasion resistance and environmental performance.
Available options: PVC, PP, PA6, PE, TPE and TPEE.
The final material combination can be selected according to the cable design and operating conditions.
Key Performance Characteristics of Flat Wrap Cable Outer Casing
Mechanical Protection
The reinforced casing helps protect control cables against external abrasion, impact, compression and puncture during installation and operation.
Controlled Flexibility
The flat-wrap construction provides structural support while allowing the casing to follow controlled cable routing paths and bends.
Low-Friction Cable Movement
Appropriate liner materials can reduce friction between the cable and casing, which is particularly important for control cables that move repeatedly.
Temperature Performance
Different liner and coating materials can be selected according to the application’s operating temperature and environmental conditions.
Environmental Resistance
The outer coating can provide additional protection against moisture, contaminants, abrasion and other external conditions.
Application-Specific Configuration
Rather than using a single fixed material combination, the casing can be configured according to the actual requirements of the cable system.
Flat Wrap Cable Outer Casing vs. Other Cable Conduit Types
Different reinforced conduit constructions provide different combinations of flexibility, mechanical protection and cable movement. The right choice depends on the cable system and installation environment.
| Type | Construction | Main Characteristic | Typical Use |
| Flat Wrap Cable Outer Casing (Spring Tube) | Rectangular-section steel wire spiral winding structure | Excellent flexibility and good compression resistance due to spiral structure; offers a balance of protection and flexibility | Control cable systems; suitable for cable protection in agricultural machinery, automotive, marine, and other industries |
| Round-Wire Reinforced Conduit | Round metal wire spiral reinforcement | Simple and cost- effective structure; provides fundamental mechanical protection | General cable external protection; suitable for agricultural machinery, automotive, marine, and other conventional environments |
| Double-Wire Reinforced Conduit | Co-wound by one flat wire and one round wire | Enhanced structural stability and improved resistance to deformation; provides stronger structural support for demanding conditions | Demanding cable systems (e. g., frequent bending or vibration); applicable to agricultural machinery, automotive, marine, etc. |
| Push-Pull Outer Casing | Lightweight materials with special reinforced construction | Lighter weight, specially designed for push-pull operation, good flexibility | Automotive door locks and other lightweight push-pull control systems also usable for control cables in agricultural machinery and marine applications |
When Is Flat Wrap Casing a Suitable Choice?
Flat wrap cable outer casing is worth considering when a cable system requires a combination of:
- Mechanical reinforcement
- Controlled flexibility
- Cable routing support
- Low-friction cable movement
- Custom liner and coating options
- Application-specific dimensions
The final selection should be based on the cable diameter, movement, bending requirements, operating temperature, environmental exposure and required protection level.
Customized Flat Wrap Cable Outer Casing
Keli provides fully customized flat wrap cable outer casing for different cable designs, installation conditions and operating requirements. We can adjust the casing structure, dimensions, materials and finishing based on customer drawings, samples or application specifications.
Customization Options
- Dimensions: Customized ID, OD, wall thickness and casing length
- Steel Reinforcement: Flat steel wire specifications and reinforcement configuration
- Inner Liner: PE, POM, PTFE, PA or PBT according to cable movement and operating conditions
- Outer Coating: PVC, PP, PA6, PE, TPE or TPEE
- Appearance: Custom colors, surface finish and marking requirements
- Tolerance: Dimensional tolerances matched to the cable assembly and installation requirements
- Packaging: Customized coiling, cutting, labeling and packaging
Built Around Your Application
Keli can develop the casing according to the actual cable application rather than relying on a standard size. Customers can provide a technical drawing, existing sample or basic application requirements, and our team can help determine the appropriate dimensions, reinforcement, liner and coating configuration.
From prototype development to volume production, Keli supports OEM/ODM customization and application-specific manufacturing for automotive, aerospace, medical, semiconductor and industrial cable systems.
Flat Wrap Cable Outer Casing Manufacturing Process
Steel Wire Inspection
Liner Tube Inspection
Raw Material (Pellet)
Inspection
Flattening
Tube Winding
Plastic Coating
Coiling & Boxing
Finished Product Inspection
Flat Wrap Cable Outer Casing Quality Control & Testing
Consistent dimensions and mechanical characteristics are important for control cable casing because variations can affect installation, cable movement and system performance.
Keli’s inspection process can cover:
Dimensional Control
- Inner diameter
- Outer diameter
- Wall thickness
- Length
- Straightness
- Dimensional tolerance
Performance Control
- Stiffness
- Bending behavior
- Shrink-back performance
- Surface quality
- Finished product consistency
Quality checks are incorporated throughout production to identify dimensional and process variations before finished products are released.
Applications of Flat Wrap Cable Outer Casing
Flat wrap cable outer casing is designed for cable systems that require controlled routing, mechanical support and reliable protection in demanding operating environments. Keli provides application-specific configurations for automotive, aerospace, semiconductor and medical equipment.
Used for control cables and mechanical cable systems where compact routing, flexibility and resistance to vibration and abrasion are important. Customized dimensions and material combinations help the casing integrate with different vehicle cable layouts.
Suitable for cable systems in aerospace equipment where lightweight construction, dimensional consistency and reliable protection are critical. Keli can customize the casing configuration according to installation space, cable movement and operating conditions.
Applied to cable routing inside precision manufacturing and automation equipment. The casing helps provide organized cable movement and mechanical protection while supporting the dimensional and cleanliness requirements of semiconductor equipment.
Used in medical and diagnostic equipment where controlled cable movement, compact routing and consistent dimensional performance are required. Keli can configure the liner and outer coating according to the equipment design and operating environment.
How to Choose the Right Flat Wrap Cable Outer Casing
Selecting a suitable casing requires consideration of the cable itself as well as the operating environment.