In the modern world, cables play a vital role in many areas, including power transmission, data communication, and industrial automation. They have a wide range of uses, from the automotive industry to the defense industry, from medical devices to the aerospace sector. With technological advancements, cables are becoming more durable, efficient, and reliable, while production processes are accelerated by automation systems. Cable production is a process consisting of various stages to obtain products with high electrical and mechanical performance. The materials, production techniques, and processing technologies used in this process vary depending on the cable’s intended use.

Cable Production Steps Cable production processes consist of various stages to obtain products with high electrical and mechanical performance. The materials, production techniques, and processing technologies used in this process vary depending on the cable’s intended use. The cable production stages can be summarized as follows:

Wire Drawing: In the first step of cable production, the copper or aluminum wires, the cable’s primary conductor, are passed through special dies and thinned. This step is performed to reduce the wire’s diameter and increase its flexibility. Annealing: The drawn wires are softened through a controlled heating process, as they harden. This increases the conductivity of the wires and optimizes their mechanical strength. Core Formation: Thin wires are bundled together in the desired number and the core formation step is performed. These cores can be single-stranded or stranded. Stranded cores provide greater flexibility to the cable. Stranding: Multiple wires are twisted together to form stranded conductors for improved conductivity, mechanical strength, and flexibility. Insulation Coating: An insulating coating such as PVC, XLPE, Teflon, or rubber is applied to the outside of the conductor to provide electrical insulation. Inner Sheath Coating (Filling): A filler coating may be applied to fill the voids around the twisted cores and give the cable a rounded shape. Outer Sheath Coating: To protect the cable from external factors, an outer sheath coating of materials such as PVC, polyethylene, or rubber is applied. The outer sheath material should be selected based on the cable’s intended use and the conditions it will be exposed to. Testing and Quality Control: At the end of the cable process, the cables must undergo electrical, mechanical, and environmental testing. Compliance with standards is verified by performing tests such as high voltage, insulation resistance, and fire resistance. Cable Processing Processes Cable processing processes encompass the processes used to make raw cables suitable for their intended use. Cable processing, which requires high precision and quality, particularly in fields such as automotive, electrical and electronics, telecommunications, and industrial automation, is performed with automatic or semi-automatic cable processing machines. The cable processing stages can be summarized as follows:

Cutting: Cable cutting machines are used to prepare cables to specified lengths. Strip Stripping: In this stage, the insulation on the ends of the cut cables is stripped without damaging the conductors. The stripping process can be partial, full, or multi-layered. Connector Crimping: In this stage, suitable connectors are mechanically compressed onto the cable ends. Soldering: In some special applications, cable ends or connector connections are soldered to ensure a more secure connection. Cable Bundling and Protection: This process is used to organize multiple cables and provide mechanical protection. Testing and Quality Control: At the end of the cable processing process, the produced cables are tested for conformity. In cable processing processes, technologies such as cable cutting and stripping machines, extrusion technology, testing and control systems are generally used.