Custom Cable Options: Tapes, Wraps, and Fillers

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Posted On:
May 24, 2021

May 10th, 2018 - Does your cable need increased flex life? Will it need to perform in extreme temperatures? Worried about cross-talk? These concerns can be addressed with the addition of tapes, wraps, and fillers to your custom cable design. There are many different tape and filler options that are available. Some of our more commonly used materials are listed below, but there are additional materials that can be utilized depending on your unique application’s needs. These material options can be applied at various operations to achieve a range of functions and offer a number of benefits, including the following:

Tapes & Wraps can:

  • Offer noise suppression or elimination of cross-talk between inner components
  • Add shielding and isolation

Commonly used materials:


  • Separator between core and jacket
  • Light weight and flexible
  • Least expensive

Mylar (polyester)

  • Binds components or entire cable
  • Opaque, clear, or aluminized
  • Cost effective
  • Less flexible

Spun Nylon

  • More flexible
  • Light weight
  • More expensive


  • Most expensive
  • Superior flexibility
  • Chemical

Fillers are often times used due to one of the following:

  • ‘Fill in’ gaps to make a cable round and more aesthetically appealing
  • Increase flex life depending on coverage and material used
  • Protect from moisture and chemicals
  • Easier molding and sealing in glands
  • Water blocking options available

Commonly Used Materials:

  • Polyolefin
  • Cotton
  • Extruded thermoplastics
  • Paper
  • Strings and yarns

If you are looking for more than one function in your tape, wrap, or filler, do not fear. These are very customizable and their coverage can range from full to minimal depending on your needs. If interested in learning more, check out our Extreme Materials White Paper.

If a long flex life, insulation, moisture protection, or extreme temperature consideration is something your cable needs, a tape, wrap or filler might be a good addition to your custom cable design. If you have questions or want to talk with an expert give us a call