Wire and Cable Extrusion

Extrusion process

During the extrusion process, wire and cable is coated with a protective sheathing or insulation using a specific type of material – typically a thermoplastic such as Polyvinyl Chloride (PVC) or Polyethylene (PE). The plastic is first melted in an extruder, which then forces the liquefied plastic into what is known as a crosshead die. 

The actual coating or extrusion of the wire occurs in the crosshead die where the wire is pulled through the die containing the liquefied plastic. As the coated wire exits the die, it is immediately immersed into a water bath that cools and sets the meted plastic onto the conductor. During the extrusion process, extrusion operators continuously inspect cooled wire for compliance with size as the product is coiled onto a spool.

At Mercury Wire, we offer a broad selection of dies and crossheads that accommodate a variety of sizes and configurations. Our processes and equipment are designed to handle traditional jackets, foam skin, and customized coatings. Our capabilities and expertise allow us to provide you with high quality extrusion processes including:

  • Single Layer
  • Dual Layers
  • Multi-Layers
  • All with Multiple Stripping and Printing Options