High-Voltage Wire and Cable | Teledyne Reynolds UK

Performance

Multiple insulation options: FEP, PFA, silicone rubber, and hybrid Ready-to-Bond configurations
Voltage ratings from 3kVDC to 60kVDC across extensive product portfolio
Lightweight, flexible design with smaller diameters than industry standard wire
Temperature range -55°C to 125°C for extreme environment operation
Altitude-rated performance from sea level through 70,000 feet
100% dielectric strength testing and optional partial discharge verification

Benefits

Reduced system weight and volume with compact, high-performance designs
Enhanced reliability through proprietary low-corona manufacturing processes
Simplified assembly with Ready-to-Bond technology for superior encapsulation
Extended service life in harsh aerospace and defense environments
Comprehensive product portfolio eliminates the need for multiple suppliers
AS9100D and ISO 9001:2015 certified quality management systems

Applications

Traveling wave tubes, magnetrons, and klystrons for RF generation
Radar, LIDAR, and electronic countermeasure systems
High voltage power supplies and energy storage systems
Spacecraft propulsion and satellite systems
Laser rangefinders and night vision equipment
Semiconductor manufacturing and inspection equipment

High Voltage Wire & Cable

Teledyne Reynolds UK High Voltage Wire & Cable solutions are designed for dependable high-voltage power delivery and signal transfer in harsh environments where insulation integrity, mechanical durability and long service life are essential. These products are specified for aerospace and defence platforms, high-reliability industrial equipment, and demanding test and instrumentation systems that must withstand electrical stress, temperature cycling, vibration, and contamination risk.

High-voltage performance is driven as much by the insulation system and construction quality as by nominal ratings. The right HV wire or cable helps reduce the risk of partial discharge, arcing, and surface tracking by supporting appropriate insulation coordination and stable dielectric behaviour over time. In practice, this means more predictable system performance, fewer field issues, and smoother qualification for programmes with strict reliability requirements.

Reynolds UK high voltage wire and cable is typically selected to align with the full operating envelope—steady-state voltage, transients, pulse duty, and environmental exposures—while meeting mechanical needs such as flexibility, bend radius, abrasion resistance, screening, and robust terminations. When combined with the correct connectors and strain relief, these cables become a critical part of a reliable high-voltage interconnect system.

Where high voltage wire & cable is used

High-voltage power distribution: routing HV safely through compact equipment and enclosures
Pulsed-power systems: charging, discharge, and energy transfer paths
High-reliability instrumentation: HV measurement, test rigs, and calibration equipment
Aerospace and defence platforms: ruggedised systems exposed to vibration and thermal cycling
Harsh industrial environments: contamination, fluids exposure, and abrasion risks

Key benefits

Robust insulation systems designed to withstand high electric field stress
Improved reliability through stable dielectric performance and controlled construction
Mechanical durability for vibration, handling, and abrasion exposure
Integration flexibility to support shielding, grounding, and routing requirements
Programme support for documentation, traceability and qualification needs

Selection guidance

Choosing the right high voltage wire or cable starts with the electrical envelope and then confirms mechanical and environmental constraints. If your system is pulsed, include pulse shape and repetition rate—those factors can be as important as the voltage rating.

Working voltage & transients: maximum steady-state voltage plus expected surge/overshoot
Pulsed duty: peak current, pulse width, repetition rate, and expected life cycles
Insulation coordination: altitude, humidity, contamination class, and required creepage/clearance at terminations
Construction: conductor type, insulation thickness, jacket materials, and abrasion resistance
Flexibility: minimum bend radius, routing constraints, and cable motion (static vs dynamic)
Shielding/grounding: EMI requirements and preferred screening strategy
Terminations: connector compatibility, strain relief, potting/overmould needs, and installation practices

Integration tips

High-voltage cable performance is often determined at the terminations. Maintain cleanliness, avoid sharp edges that concentrate electric fields, use appropriate strain relief, and ensure creepage/clearance is preserved in the final assembly. Where required, follow a consistent grounding approach for screened cables to reduce noise coupling and improve system stability.

Related links: Reynolds UK products | Reynolds UK overview

Frequently Asked Questions

1) What makes wire or cable “high voltage”?

High voltage wire and cable uses an insulation system designed to withstand elevated electric field stress without breakdown, tracking or unacceptable leakage. Selection is based on maximum working voltage (including transients), environment, and how the cable is routed and terminated.

2) Why do transients matter as much as the nominal voltage rating?

Many HV systems experience switching surges, overshoot, or fast rise-time pulses that can exceed steady-state levels. Those transients can drive partial discharge or breakdown if not accounted for. Always include transient levels and waveform information in the selection process.

3) What details do you need to recommend the right HV cable quickly?

Maximum working voltage and transients, current and duty (continuous and/or pulsed), temperature range, routing constraints (bend radius, motion), EMI/shielding needs, exposure to abrasion or fluids, and the connector/termination requirements.

4) How do altitude and environment affect HV cable selection?

Altitude can reduce the dielectric strength of air around terminations, and humidity/contamination can increase surface tracking risk. These conditions influence insulation coordination, termination design, and required creepage/clearance—often affecting both cable choice and how it’s installed.

5) Do I need shielded (screened) high voltage cable?

Screening may be required if your system needs EMI control, reduced noise coupling, or a defined grounding approach for performance or safety. If EMI is not a concern, an unscreened cable may be adequate, depending on routing and separation in the assembly.

6) What are the most common causes of HV cable issues in the field?

Many problems occur at terminations: contamination, insufficient strain relief, sharp edges causing electric field concentration, or inadequate creepage/clearance. Mechanical damage, tight bend radii, and improper grounding of screened cables can also reduce reliability.

7) Is HV cable suitable for pulsed-power and capacitor discharge applications?

Yes, but pulsed applications require matching the cable to peak current, pulse width, repetition rate, and thermal effects. Provide the pulse profile and expected duty so the insulation system and construction can be aligned with the application.

8) Can you provide complete cable assemblies with connectors and strain relief?

Yes. Many programmes prefer complete assemblies to reduce integration risk. Share your voltage/current envelope, required length, connector interface, shielding needs, and any test/inspection or traceability requirements to define a build-to-spec assembly.