COMPOUNDS | WIRE AND CABLE


reliable electromagnetic interference (EMI) protection but comes with trade-offs such as added weight, limited flexibility, and challenges in recyclability. Graphene-enhanced polymer com- pounds offer an alternative. By embedding conductive graphene nanoplatelets into thermo- plastic matrices, it becomes possible to create functional shielding layers directly within the cable jacket or as a coated layer, reducing reliance on metallic components. The system presented combines a standard


Graphenest has developed a system combining a standard Cat.6A S/FTP cable architecture with a graphene-enhanced conductive layer (trade name G-Shield) integrated into a PVC-based structure Source: Graphenest


reliable long term performance, supporting advancement through qualification programs. To spearhead this momentum, Orion is expanding specialty carbon black capacity, including a new greenfield acetylene black facility in La Porte, Texas, the only plant of its kind in the US, strengthening supply reliability for North American compounders.


Novel approaches Manufacturers are offering alternatives to high- performance fluoropolymers used for insulation in wire and cable extrusion applications. Regulatory restrictions or outright bans on per- and polyfluoro- alkyl substances (PFAS), which includes fluoropoly- mers, are being considered worldwide. Sabic’s family of Siltem resins, polyetherimide-siloxane (PEI-Si) copolymers formulated without fluorine, offer a potential solution. One approach to addressing the performance gap is to formulate PEI-Si copolymers with semi- crystalline and elastomeric building blocks. Certain semi-crystalline resins can enhance heat and chemical resistance, while elastomeric materials can improve flexural fatigue resistance and elongation at break. Sabic representatives say the company has developed several promising PEI-Si resin blends and conducted extensive evaluations on samples using in-house lab facilities. Overall, testing showed that each of the new blends achieved performance improvements compared to standard PEI-Si resins, notably in chemical resistance. A recent development by Graphenest high- lights how advanced conductive compounds help shielding strategies for Cat.6A high-speed data cables. Traditional shielding, typically involving metallic braids and/or aluminium foils, offers


32 COMPOUNDING WORLD | May 2026


Cat.6A S/FTP cable architecture with a graphene- enhanced conductive layer (trade name G-Shield) integrated into a PVC-based structure. The cable retains familiar elements, 22 AWG conductors, twisted pairs, and foil screening, while introducing the conductive polymer layer. Testing demonstrated consistent attenuation performance in the 1–500 MHz range, achieving >30 dB shielding effective- ness with values approaching 50 dB at higher frequencies, compliance with Cat.6A industry requirements, and stable performance, indicating uniform material behaviour and process consistency. Dispersion quality of graphene within the polymer


matrix is critical to achieving percolation at relatively low loadings, while viscosity control ensures compat- ibility with high-throughput extrusion processes. This positions graphene-based masterbatches as functional additives rather than fillers. “Graphene-enhanced conductive polymers are moving from niche applications toward scalable industrial adoption,” said Bruno Figueiredo, Graphenest Co-CEO & Founder. “This illustrates how material innovation, when aligned with processing realities, can deliver measurable performance improvements in established cable formats. For the compounding industry, this signals a broader trend; the evolution of polymers from passive insulators to active functional components in electrical systems.” Prysmian has launched the Sirocco Ultra, the


first microduct cable featuring 160 µm optical fibre earmarked to become an essential component in applications such as data centres. Microducts are small, flexible tubes inside the cable which form continuous paths for fibre connections, while the 160 µm optical fibre is a new best-in-class standard for high density data transfer. Combined, they unlock greater efficiency, reliability, and flexibility, reducing deployment costs and accelerating installation times. “We set a new standard of fibre miniaturisation, and now we can unlock unpredicted cable density,” said Ian Griffiths, Vice President of R&D for the Digital Solutions segment at Prysmian. “This means


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