FibreMax production method.

FibreMax lightweight precision cables are produced by using an unique and one-of-a-kind production process. All cables are produced with endless winding technology which is a totally automated process of continuous winding of parallel strands of fibres around two end fittings until the right cable strength or required cable stretch has been reached. After the required length has been programmed, the EWR (endless winding robot) computer calculates the amount of fibres and the amount of loops required for the specified cable. During the winding process the EWR maintains an equal tension in all fibres with an accuracy of 0,1%. This results in the highest break load, lowest stretch and lowest possible diameter. It also ensures that cables are produced with high repeatability; when producing multiple cables we can garantuee that all cables will have exactly the same specifications. 

When the desired amount of loops has been reached the cable is compressed by a strong and lightweight "wrap-around" tape to ensure minimal diameter and protection of the fibres. After this tape has been wrapped around the cable, another light, but strong, heat-shrink tape is automatically wrapped around the cable. These two layers of tape act as a particle filter layer to limit the amount of particles from protruding and destroying the fibres.

After the cable has been sealed a "bullet-proof" braid of Dyneema® or aramid is applied to ensure protection against wear and abrasion. When needed the cable can be provided with a special low drag surface to reduce vortex-induced vibration (VIV). Because of their very light weight FibreMax cables already have a higher natural frequency than steel wire ropes.

A special coating can be applied to improve the properties of the protective braids. The colour of this coating can be adapted to customer's request. Other protection methods are available upon request. All cables are equipped with a RFID track-and-trace system which gives information on all production data of the cable. This will allow our service department to identify any cable in the event of a return for service or testing.

The unique endless winding production process also means that the terminations (or end fittings) of the cable are directly incorporated. These terminations are specially designed to match the desired cable properties and to support the amount of fibres. The dimensions of these terminations are almost twice as small as can be accomplished by standard wire/rope manufacturers. The terminations are designed to support full 100% MBL. The terminations are vacuum sealed with PU to ensure a perfect water tightness.