Premier Manufacturer
The Secret Behind Reliable Coiled Cables? Engineering Discipline and Real-World Testing.
Have you ever stretched a coiled cable and it never rebounded to its original shape? This is what occurs when precision is lost.
At Romtronic, we transform frustration into dependability by designing, engineering, and manufacturing unique coil cable assemblies that withstand thousands of cycles in any industry that cannot afford downtime. Learn more about choosing the right components in our How to Choose the Right Coil Cable Assembly – Buyer’s Guide.
Why Coil Cable Assemblies Matter
Coiled cables are the underappreciated heroes of motion.
They keep industry robots flexible, medical devices mobile, and test instruments clean and accurate.
A good coil cable can extend and retract without damaging the signal or the sheath.
Not all coils are created equal. Some stretch too much and snap; others lose shape within months. Romtronic’s precision winding, controlled heat setting, and tailored strain relief ensure durability and flexibility.
Our Step-by-Step Manufacturing Process
Step 1 – Design Consultation
We start with your specifications: environment, voltage, bend radius, and connector type.
Then, our engineering team (each with CAD and Pro-E knowledge) creates the optimum coil geometry to maintain consistent elasticity.
Step 2 – Material Selection
Each jacket, conductor, and filler counts. Here’s how we evaluate options:
| Material Type | Key Strength | Ideal Applications |
|---|---|---|
| PUR (Polyurethane) | High flexibility, oil & abrasion resistance | Industrial robots, automation |
| TPE (Thermoplastic Elastomer) | Elastic and chemical-resistant | Medical & handheld devices |
| PVC (Polyvinyl Chloride) | Cost-effective, flame retardant | Office or test equipment |
| Silicone | Extreme temperature endurance | Aerospace, medical instruments |
Before production, materials undergo bending, twisting, and thermal stress tests to ensure their integrity and reliability. For more guidance on selecting jacket materials, refer to Choosing Jacket Material: PVC vs. TPE vs. PUR vs. LSZH vs. Silicone.
Step 3 – Precision Coiling
We use CNC-controlled coil winding equipment to produce tight, uniform spirals.
Each coil is then heat-set to permanently save its memory, revealing the key to a cable that always springs back flawlessly.
Step 4 – Overmolding & Assembly
Connectors, strain reliefs, and overmolded ends are used for both functional and aesthetic reasons.
This ensures mechanical protection and a clean, professional finish, regardless of whether the interface is USB, M12, or a unique pin. Learn more about 360° Shield Termination Methods for added durability techniques.
Step 5 – Testing & Quality Assurance
Every coiled cable assembly underwent:
- 100% continuity testing
- Tensile and torque validation
- Cycle life simulation (10,000+ extensions)
We do not ship any assemblies unless they meet Romtronic’s durability standards, which exceed most OEM specifications.
What Makes Romtronic Different
Engineering Focus
We aren’t just cable assemblers; we’re issue solvers.
Whether you require a retractable Ethernet cable for factory sensors or a spiral power cord for portable medical devices, we can customize any design to meet your needs.
Real Case: Medical Mobility Success
A German medical equipment manufacturer required a 12-conductor retractable coil for a patient monitoring system.
Following numerous failures from other manufacturers, Romtronic modified the cable with TPE insulation and double-layer strain relief, increasing its longevity by 80%.
Today, the same design powers more than 40,000 machines worldwide.
Customization Beyond Specs
Do you require color-coded wires, molded logos, or IP-rated terminations?.
Romtronic’s versatile production lines enable small-batch prototyping to full-scale runs, with quick turnaround and global delivery.
Service Areas
Our reliable coil cable assemblies are widely used in:
- Industrial automation
- Medical diagnostics & mobility
- Aerospace and avionics
- Test & measurement systems
- Consumer and wearable devices
Every project begins with your challenge and concludes with a cable solution perfectly tailored to your dynamic environment.
Common Questions (FAQ)
A: Usually 3-5 times its resting length, depending on the material and pitch design.
A: Absolutely. We provide bespoke molding and matching for new and legacy systems.
A: Standard prototypes take 2-3 weeks; production times vary depending on complexity and order size.
A: Yes, Romtronic cables meet UL, RoHS, and REACH requirements. Additional testing is available upon request.
A: Yes. We frequently design for environments that require protection against oil, UV, vibration, and extreme temperatures.
From Prototype to Production — Fast
There are no long delays. There are no lost details.
Romtronic controls the entire process, from design concept to final packaging, under one roof.
This is how we ensure constant quality and predictable delivery.
Ready to Build Your Custom Coil Cable?
Whether it’s 10 prototypes or 10,000 production units, we provide precision, speed, and dependability.
Talk to a Romtronic engineer today.
👉 Request a Quote or Discuss Your Project
Sam Wu is the Marketing Manager at Romtronic, holding a degree in Mechatronics. With 12 years of experience in sales within the electronic wiring harness industry, he manages marketing efforts across Europe. An expert in cable assembly, wiring harnesses, and advanced connectivity solutions, Sam simplifies complex technologies, offering clear, actionable advice to help you confidently navigate your electrical projects.
