Engineered Here. Manufactured Here. Built to Perform.
From custom compounds and precision extrusion to complex cabling, irradiation, and testing, Champlain Cable brings critical engineering and manufacturing capabilities together to produce high-performance wire and cable for demanding applications.
Overview
From Engineering Concept to Production
BUILT AROUND YOUR APPLICATION
Every cable starts with a performance requirement. Our materials scientists and mechanical and electrical engineers work together to develop constructions around the electrical, thermal, mechanical, environmental, and processing demands of each application.
By combining engineering, proprietary material technologies, advanced manufacturing processes, and in-house testing, Champlain Cable can take a solution from initial concept through repeatable production—all with a focus on long-term reliability.
MANUFACTURING EXPERTISE
Our manufacturing capabilities include extrusion, cabling, braiding, jacketing, irradiation, and fluid blocking. Advanced process controls and specialized equipment help maintain dimensional consistency and repeatable performance across a broad range of wire and cable constructions.
Precision at Every Stage
EXTRUSION
Copper conductors move through precision extrusion equipment where engineered polymer compounds are applied under controlled processing conditions to create high-performance insulation systems.
Precise control of material, temperature, line speed, and dimensions helps produce consistent insulation engineered for demanding applications.
COOLING & TAKE-UP
After extrusion, insulated conductors pass through controlled cooling systems before being collected onto reels for subsequent manufacturing operations.
Careful process control helps preserve dimensional consistency and prepares each conductor for the next stage of production.
CABLING
Individual insulated conductors are brought together using twinning, quadding, and planetary cabling equipment to create constructions ranging from simple pairs to complex multi-conductor cables.
The process can incorporate tapes, separators, shielding components, and other construction elements based on application requirements.
BRAIDING & JACKETING
Braiding and shielding can be incorporated to provide mechanical protection and support electrical performance in demanding environments. Outer jackets add another layer of protection against abrasion, chemicals, fluids, temperature, and other environmental challenges.
ELECTRON BEAM CROSS-LINKING
Cross-linking enhances temperature capability, abrasion resistance, chemical resistance, and long-term durability while maintaining the flexibility required for demanding wire and cable applications. Champlain’s current capabilities page states its irradiation systems support thermoset insulation systems rated for continuous use from -70°C to 250°C.
Our Expertise
Manufacturing Range, Built-In
Champlain Cable combines advanced equipment, proprietary materials, engineering expertise, and tightly controlled processes to manufacture wire and cable across a broad range of sizes and constructions.
MINIMUM WIRE SIZE
MAXIMUM CONDUCTOR SIZE
CABLE DIAMETER CAPABILITY
Temperature performance
MORE THAN MANUFACTURING
Engineering Built Into the Process
Champlain Cable’s manufacturing capabilities are backed by multidisciplinary engineering expertise. Materials science, mechanical engineering, electrical engineering, field knowledge, and process engineering come together to solve wire and cable challenges that standard constructions cannot.
EXAR®
Engineered to withstand extreme temperatures and demanding manufacturing processes while delivering exceptional durability, flexibility, and long-term reliability.
EXRAD®
Field-proven wire and cable solutions designed for automotive and commercial vehicle applications where performance, efficiency, and durability are critical.
DATACLEAR®
High-performance data communication cables built for military, naval, and mission-critical applications where reliability and environmental resistance are essential.
DATARAD®
Advanced lead wire and Ethernet cable solutions engineered for high-temperature automotive and commercial vehicle applications.
Knowledge Center
Learn More About Our Technologies
Explore additional resources covering polymer science, insulation technologies, product innovations, and the engineering expertise behind Champlain Cable’s solutions.
CONTACT US
Let’s Solve Your Next Challenge
Have a question, project, or technical challenge? Let’s start the conversation.