Extra Flexible Double Insulated Welding and Battery Power Cable
This extra flexible double insulated welding and battery power cable is designed to handle the demanding electrical and mechanical requirements of industrial welding equipment, battery interconnection systems, and high-current power distribution. The cable combines a 100% oxygen-free copper (OFC) conductor with an ultra-fine multi-strand construction to achieve outstanding flexibility — allowing the cable to be routed through tight bends, coiled and uncoiled repeatedly, and repositioned in service without conductor fatigue or insulation cracking.
The double insulation system — a smooth inner layer bonded to a tough outer jacket — provides a substantially higher level of electrical safety than single-insulated welding cable. Should the outer jacket sustain mechanical damage during use, the inner insulation layer maintains isolation between the live conductor and ground, significantly reducing the risk of shock or short circuit in harsh workshop and field environments.
With a current-carrying capacity suitable for welding machines up to 500A and battery banks operating at voltages from 12V to 1500V DC (depending on insulation grade selected), this cable is equally at home in automotive battery assembly lines, solar energy storage cabinets, EV charging infrastructure, and traditional arc welding operations.
Technical Specifications
| Parameter | Specification |
|---|---|
| Conductor material | 100% oxygen-free copper (OFC), fine stranded |
| Conductor class | Class 6 (IEC 60228) — extra flexible |
| Insulation — inner layer | PVC or EPDM rubber (grade dependent) |
| Jacket — outer layer | Neoprene (CR) or EPDM rubber |
| Temperature rating | –40°C to 105°C |
| Voltage rating | Up to 1000V AC / 1500V DC |
| Available cross-sections | 16 mm² – 120 mm² (6 AWG – 4/0 AWG) |
| Flame rating | IEC 60332-1, UL VW-1 |
| Standard | IEC 60245, GB/T 12528, RoHS compliant |
| Color options | Black, red, yellow, custom |
| Packaging | 50 m / 100 m coils or custom drum lengths |
Cross-Section Reference Table
| Cross-section | AWG equiv. | Strand count | Approx. OD (mm) | Max current (A, in air) | Resistance (Ω/km) |
|---|---|---|---|---|---|
| 16 mm² | 6 AWG | 252 | 11.2 | 110 | 1.15 |
| 25 mm² | 4 AWG | 392 | 13.0 | 140 | 0.727 |
| 35 mm² | 2 AWG | 546 | 14.8 | 175 | 0.524 |
| 50 mm² | 1/0 AWG | 756 | 17.2 | 215 | 0.387 |
| 70 mm² | 2/0 AWG | 1058 | 20.0 | 265 | 0.268 |
| 95 mm² | 3/0 AWG | 1440 | 23.0 | 315 | 0.193 |
| 120 mm² | 4/0 AWG | 1824 | 25.5 | 360 | 0.153 |
Key Features
Conductor & flexibility
- 100% oxygen-free copper — zero conductivity loss from impurities
- Class 6 fine stranding — maximum flexibility and fatigue resistance
- Minimum bend radius 4× OD — easy routing in confined spaces
- No conductor memory — cable lies flat after coiling
- Strand count up to 1,824 wires (120 mm²)
Insulation & safety
- Double insulation — inner layer retained if outer jacket is damaged
- –40°C to 105°C operating range
- Oil, abrasion, and tear resistant outer jacket
- Self-extinguishing flame rating (IEC 60332-1)
- RoHS compliant — no restricted heavy metals
- High current capacity — up to 360A continuous for 120 mm² cross-section in free air
- UV and ozone resistant jacket — suitable for outdoor battery installations and solar storage
- Excellent chemical resistance — withstands battery acid, welding spatter, oils, and cutting fluids
- Wide voltage range — rated up to 1000V AC / 1500V DC to cover EV and BESS applications
- Custom termination — available with compression lugs, ring terminals, or bare ends
Common Applications
Industrial welding
The primary use case for this cable is as a welding lead — the flexible cable connecting the welding machine to the electrode holder (whip) and the work return clamp. The Class 6 fine stranding allows the welder to freely manipulate the electrode without the cable stiffening or fatiguing at the connection points. The double insulation provides critical safety margin when the outer jacket is inevitably abraded by workshop floors, steel edges, and welding spatter over time.
Battery interconnection & energy storage
Used extensively for cell-to-cell and module-to-module interconnections in lithium battery packs, lead-acid battery banks, and large-format BESS (Battery Energy Storage Systems). The 100% OFC conductor minimises resistive losses at the high currents drawn during charge and discharge cycles, and the fine stranding allows the cable to be routed around battery module corners without stress concentrations at the terminations.
EV charging infrastructure
Suitable for DC fast charger (DCFC) flexible cable between the charger unit and the vehicle connector, where a combination of high DC voltage (up to 1000V), high continuous current, and repeated coiling and uncoiling demands both electrical performance and long mechanical service life.
Automotive & marine
Widely used as starter cables, alternator cables, and battery-to-distribution connections in commercial vehicles, marine vessels, and off-road equipment where vibration, chemical exposure, and wide temperature swings are routine.
Other applications
- Solar PV string-to-battery and inverter connections
- UPS and backup power system wiring
- Forklift battery and charging lead replacement
- Industrial generator output cables
- Plasma cutting machine leads
Double Insulation vs. Single Insulation — Key Differences
| Property | Double insulated (this product) | Standard single insulated welding cable |
|---|---|---|
| Insulation layers | 2 (inner + outer jacket) | 1 |
| Safety after outer damage | Inner layer maintains isolation | Conductor exposed immediately |
| Voltage rating | Up to 1000V AC / 1500V DC | Typically 100V – 600V |
| Suitable for battery/EV use | Yes | Limited |
| Abrasion resistance | Higher (two layers to penetrate) | Standard |
| Weight | Slightly heavier | Lighter |
Ordering Information
Select cross-section, jacket material (Neoprene or EPDM), color, and length from the product options above. Custom orders including non-standard cross-sections, printed outer jackets, and pre-terminated assemblies with compression lugs are available from 200 m minimum order quantity.
Test reports available. Third-party test reports (SGS, BV, ITS) covering conductor resistance, insulation resistance, voltage withstand, and flame test are available on request. Contact us for a factory quotation within 24 hours.
Why Choose CableApex
Our welding and battery cables are produced on dedicated extrusion lines with 100% online spark testing at 8 kV and continuous laser OD measurement to guarantee insulation integrity on every meter. All oxygen-free copper rod is sourced from certified smelters with material traceability certificates. We supply direct to welding equipment OEMs, battery pack assemblers, EPC contractors, and cable distributors across more than 40 countries with standard lead times of 10–20 working days.
