Precision Manufacturing Capabilities for Inner Wire Core Systems
Producing a high-performance inner wire core isn’t just about
material — it’s about how it's made. At Phidix, our manufacturing system follows IATF 16949 standards,
ensuring every meter of cable meets exacting standards for
mechanical control systems in automotive, rail, agricultural, and
industrial applications.
This page showcases how our capabilities go beyond basic production
— they represent our commitment to safety, consistency, and motion
accuracy.
IATF 16949: The Backbone of Our Quality System
We are proud to operate under the IATF 16949 automotive quality
system, which enables:
• Full process traceability (from raw material to finished coil)
• Statistical quality control on tensile and diameter tolerances
• Lot-based documentation and inspection data
• Zero-defect tracking system with long-term recall integrity
Whether you're sourcing cores for high-volume motorcycles or
one-off control prototypes, our process ensures repeatable
performance and guaranteed quality.
Core Manufacturing Process Overview
| Step | Description |
|---|
| Wire Drawing | High-precision diameter control using corrosion-resistant stainless
steel (304/316L). |
| Stranding | Tight-tolerance twisting into 1x7, 1x19, 7x7, 7x19 configurations. |
| Pre-stressing | Eliminates initial stretch, stabilizes cable under load. |
| Coating (optional) | PTFE, HDPE, or Zine-coated for friction and corrosion control. |
| Inline Inspection | Diameter, surface, twist pitch, and tensile properties verified at
every stage. |
| Custom Cutting & Packaging | Cut-to-length, coiled, or ready for cable assembly. |
Quality Control Measures
| Test Type | Purpose |
|---|
| Tensile Test | Confirms strength matches design spec |
| Fatigue Test | Validates performance over motion cycles |
| Diameter Tolerance | ±0.02mm or tighter based on spec |
| Strand Uniformity | Prevents uneven wear or vibration |
All tests are logged in digital QC reports per batch.
Customization Capabilities
We offer full customization to match specific system needs:
• Strand configuration: 1x7 / 1x19 / 7x7 / 7x19 / solid
• Length precision: cut-to-length tolerance ±0.5mm
• Surface finish: raw, PTFE-coated, Zine-coated, polymer sheath
• Packaging: coil, reel, or section-based box delivery
OEM clients may also request serialized laser-marking or batch trace codes.
End-to-End Integration with Control Assemblies
Our inner wire cores are engineered to fit seamlessly into:
• Push-pull cables
• Remote throttle/choke cables
• Damper and vent control assemblies
• Multi-cable actuator modules
If you are integrating inner wire cores into high-stress,
high-frequency systems, we can also supply matched outer conduit,
end fittings, and termination services under the same IATF quality
scope.
Matched inner and outer cable assembly sample manufactured by
Phidix
Expert Validation
Our process is based on guidelines outlined in:
• Cablecraft Motion Control Design Guide – for stranding geometry, tensile stability
• CMA Safety Restraint Guide – for fatigue control and permanent elongation management
These ensure your control system will not only work—but last.
Related Technical Pages
• Inner Wire Core Selection Guide
• Failure Mode & Preventive Design
Get Engineering Support
Need a build-to-print inner core solution? Share your drawings or
specs and our engineering team will provide feasibility feedback,
samples, and full DFM recommendations within 48 hours.
Aircraft-Grade Mechanical Control Cables: 7x7 to 7x19 Strand Configurations
