What is Bend Radius?

When designing an electronic product, accommodating the required cabling in order to create the most compact, efficient design possible is a key consideration.

Whether using a cable assembly or wire harness, the configuration of your wiring within its intended application is vital.

In order to accommodate these design features, wire harnesses are typically constructed on a loom board, which gives an indicative layout of its layout within the product’s enclosure.

The bend radius – the radius at which a cable can be bent without being damaged – is therefore a key consideration of individual cable construction within a product’s design.

Why is cable bend radius important?

Bend radius is important for a number of reasons. The bending radius of a cable helps ensure a cable’s structural integrity and durability. Knowing and understanding the maximum radius that a cable can be bent at without being damaged means that electronics manufacturers can ensure the long lifespan of their product’s internal wiring.

Due to cable jacketing, bending cables beyond a minimum bend radius may not display visible damage. However, the conductors, insulation and shielding can easily become damaged, significantly reducing the cabling’s lifespan.

The required cable bend radius will also affect the design of the cable itself – the smaller the required bending radius, the smaller the outer diameter (OD) of the cable must be. A cable’s OD is already a critical consideration in electronics system design, determining the cable’s size and suitability for specific connectors and routing.

On top of this, cables that overstep their bend radii increase the risk of short circuits, and subsequently electric shocks and fires.

Does the bend radius change at extreme temperatures?

When manufacturing electronics for use in specialist applications, such as the industrial sector or for marine use, the product in question may be exposed to extreme high or low temperatures.

The bend radius of a cable does not change when exposed to high temperatures and extreme heat. However, as with any cable, regardless of bend radius, going below the minimum operating temperature can cause the jacket to become brittle and crack.

Tight bend radius requirements

If your electronics will be installed in spaces with tight space constraints, a tight bend radius is likely to be required. When specifying your cable assembly or wire harness from GTK, we’ll work with you to deliver cables with the correct bend radius for their intended use.

We’ll advise on material selection, choosing flexible, high-quality insulation and jacket materials to accommodate tight bend radii. We can also specify finely stranded conductors using special alloys; compared to solid conductors, these provide a greater level of flexibility.