CABLES & CONNECTORS FEATURE
SPECIALIST HIGH PERFORMANCE WIRE: MADE IN THE USA, DISTRIBUTED WORLDWIDE
As a well established designer and
manufacturer of electrical wire and cable products, Insulated Wire
produces reliable
products that meet the demands of
harsh environment applications
I
nsulated Wire is a New York based designer and manufacturer of all types of electrical wire and cable products, including coaxial
cable. It was founded in 1970, focusing on the oil and gas market. The company’s initial product was developed
using a unique process for laminating Teflon, resulting in a cable that provided a higher breakdown voltage using a smaller line size than was available at the time. This then evolved into a range of wire products which are still widely used in data logging for oil exploration today. Insulated Wire’s core materials – Teflon and
silver-plated copper – provide reliable operation at high temperature in harsh environments.
MANUFACTURING
During the 1980s the lamination process was applied to coaxial cable, with the company producing a range of line sizes to support applications in the RF, microwave and millimeter wave frequency ranges. These products have been developed into the range of coaxial cable
Insulated Wire supplies today. For coax cable, the company’s
manufacturing process enables a concentric cable construction which provides tight impedance control, excellent phase stability and exceptional attenuation performance across the microwave spectrum. All cable designs are double shielded using an FEP outer jacket as standard and are also available with various jacket material options including Santoprene, low smoke/zero halogen polyurethane and Tefzel, armor and other abrasion resistant materials. The attenuation performance of the coax
makes these cable types suitable for applications where the lowest loss between antenna and the electronic system is the primary consideration and means cables – such as the 280 series (19.5 GHz cut-off) – are employed on numerous marine platforms worldwide. Insulated Wire can supply either turn-key
cable assemblies, part terminated to support intricate routing requirements, or bulk cable and connector kits to enable assembly and installation at a customer location. From down mast cables on surface ships to hull penetrators and periscope cables, Insulated Wire is experienced in providing solutions suitable for harsh environment applications.
COLLABORATION In addition to bulk cable, Insulated Wire is also able to offer composite cable solutions, which can be same or mixed signal cable types. Furthermore, the company can even ruggedise fibre optic cable and incorporate it into a composite cable design. To ensure that all requirements are documented and project managed through qualification and delivery of the final design, Insulated Wire works closely with its customer’s engineering teams. For RF/Microwave cable
assemblies, Insulated Wire offers a wide range of interconnect solutions using industry standard interfaces from high power/low frequency to millimeter wave including 3 1/8 and 1 5/8 EIA flanges, SC, C, HN, N-type (18 GHz),
TNCA (18 GHz), SMA, 3.5mm, 2.92mm, 1.85mm and 1.0mm. All connectors are
NOVEMBER 2025 DESIGN SOLUTIONS 33
solder attachment to provided optimum electrical performance and reliability.
SUPPLY CHAIN Insulated Wire has two facilities, Bayport NY for bulk cable manufacture and Ronkonkoma, NY, that produces assemblies, with AS9100 campus certification. With USA based manufacturing and the support
of a worldwide network of representatives and agents, Insulated Wire can offer standard and custom wire and cable assemblies, and provide customers with a secure supply chain.
Insulated Wire
https://insulatedwire.com/
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