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Control cables from chainflex® with low bend radii for high speeds

Control cables from chainflex® with low bend radii for high speeds

Built for extreme environments and tested for millions of cycles

Control cables are the workhorses of motion applications, carrying power and control signals to motors, drives, and actuators as a machine moves. Standard, stationary-rated cable cracks and fails when it is asked to flex and twist inside a cable carrier over millions of cycles — a failure mode that causes unplanned downtime and costly line stoppages. chainflex® continuous-flex control cables solve this with stranding and jacket constructions engineered specifically for repeated motion, available shielded or unshielded with a choice of PVC, PUR, and TPE outer jackets, holding up under high speeds, low bend radii, and extreme temperatures where standard cable was never designed to perform. As automation lines demand faster cycle times and tighter cable carrier geometries, more engineers are specifying continuous-flex control cable from the start, rather than replacing standard cable after it fails.

Benefits:

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Browse chainflex® control cables

CF5 PVC Control cable

PVC Control Cables

  • For heavy duty applications
  • Flame retardant
  • Silicon-free
  • UV-resistant
  • Oil-resistant according to DIN EN 50363-4-1
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CF77-UL-D PUR Control Cables

PUR Control Cables

  • For twistable applications
  • Coolant, hydrolysis, microbe and UV-resistant
  • Flame retardant
  • Halogen, silicon and PVC-free
  • Oil-resistant to DIN EN 50363-10-2
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CF9 TPE Control Cables

TPE Control Cables

  • For heaviest duty applications
  • Low-temperature-flexible
  • Hydrolysis, microbe, coolant and UV-resistant
  • Halogen, silicon and PVC-free
  • Oil-resistant according to DIN EN 60811-404
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Stage and theater with igus

igus® delivers energy systems, flexible cables, and plastic bearings designed for the unique demands of theater and stage construction, ensuring safe, reliable motion under high loads while operating quietly and out of sight.

Theater application with chainflex

This 118,000-square-foot facility features a main hall with five configurable performance modes. The center aims to foster interdisciplinary collaboration and innovation in the arts.

chainflex® Application Stories

Crane cable carrier in demanding environments

A company supplying steel rails to the international railway industry replaced festoon systems on its indoor and outdoor cranes to reduce both maintenance requirements and costs. The new energy chain systems are comprised of igus®' E4/4 Heavy Duty Series cable carriers, aluminum guide troughs and chainflex® continuous-flex cables.

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chainflex in steelworks application

Cable management for high-bay warehouse operation

In the meat-processing industry, igus® readychain® cable carrier systems streamline storage and handling in high-bay warehouses, cutting installation time from three days to just four hours, minimizing assembly errors, and reducing the risk of plant downtime—delivering reliable, efficient operation for complex storage-and-retrieval units.

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cables in food processing application

Crash simulation robots using cable carriers

Decommissioning a nuclear power plant demands precise, reliable solutions. For dismantling 46-foot steel tanks, a milling cutter powered by igus® Series 28 E4/00 energy chain carriers ensured smooth operation in zigzag applications. Guiding chainflex® CF9 continuous-flex cables and hoses, this system delivered dependable power and fluid supply, proving the durability and reliability of igus® components in the most demanding environments.

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Crash simulation robots use cable carriers

Cable Carriers and Cables for Touch-Free Car Wash Systems

A leading car wash manufacturer delivers self-service, automatic, tunnel, and freestanding car wash systems, with its touch-free car wash being a customer favorite. This state-of-the-art system handles vehicles of all sizes, including large trucks and Hummers, using advanced software and reliable components.

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Cable Carriers and Cables for Touch-Free Car Wash Systems

Large screen LED installation

The igus® E4 energy chain safeguards fiber-optic, power, and control cables on 26-foot automated LED displays at Victory Plaza, ensuring reliable operation 18 hours a day, 360 days a year. Designed for extreme weather, UV, and low-temperature resistance down to –30 °F, it outperforms competitor systems by preventing corkscrewing and premature failure, delivering a durable, low-maintenance solution for high-duty outdoor LED applications.

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chainflex in victory plaza

Automated mic reel with no signal loss

The e-spool microphone reeler extends cables up to 30 m automatically from the ceiling—no manual work, no risk of cable damage. It eliminates slip rings (a common source of interference) using a twisterband system for smooth, uninterrupted signal transmission. Built-in safety features—special XLR cable with strain relief and auto-stop on exceptional load—protect both gear and operators.

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chainflex in espool stage application

FOC with Tight Bend Radii Solutions

When copper bus cables fail under tight bend radii and millions of double-strokes, chainflex® fiber optic cables outperform with up to 40% smaller minimum bend radius and far longer service life. Fiber optics deliver high-speed data immune to EMC interference, with signal integrity preserved even when cable curvature changes—something copper cores can’t reliably maintain.

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chainflex FOC tight bend radii solutions

Belt-driven units for automatic gates

In this application, continuous-flex chainflex® CF9 TPE control cables have a much longer service life than the cables previously used. These are safely guided by igus® energy chains cable carriers from the E2 Micro family. Furthermore, the belt-drive units of the gates are equipped with tribologically optimized iglide® plastic plain bearings, which have reduced wear rate considerably.

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Cable Carriers with a Longer lifetime

Nuclear Power Plant Decommissioning

Decommissioning a nuclear power plant demands precise, reliable solutions. For dismantling 46-foot steel tanks, a milling cutter powered by igus® Series 28 E4/00 energy chain carriers ensured smooth operation in zigzag applications. Guiding chainflex® CF9 continuous-flex cables and hoses, this system delivered dependable power and fluid supply, proving the durability and reliability of igus® components in the most demanding environments.

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chainflex in nuclear plant decommissioning

Control Cables in Composting Plant

igus® roller energy chains and chainflex® cables keep composting plants running reliably in extreme heat, humidity, and abrasive environments. The roller design minimizes friction and wear, extending service life from annual replacements to over five years. Built for continuous flex and harsh conditions, these systems reduce downtime, cut maintenance, and ensure efficient, long-term operation.

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chainflex in Composting Plant

Pre-assembled energy supply for amusement park ride

With readychain®, igus® is assigned all the procurement logistics, from the purchase of all essential special parts to the safe, efficient delivery of the ready-to-install system on a fixed date. There is a number of reasons to opt for a pre-assembled cable carrier system in mechanical and plant automation. Manufacturing costs, sources of error and project planning costs are reduced, whilst reliability is increased.

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chainflex in amusement park ride

Reliable cables solution in machining centers

igus® energy chain systems for large machining centers deliver reliable, high-speed energy and media supply over long travel distances. Pre-assembled readychain® solutions simplify installation, reduce downtime, and handle heavy loads with precision. These systems keep gantry machines running smoothly while protecting cables from wear, vibration, and contamination.

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chainflex in machining center

chainflex® cables in concrete manufacturing

A manufacturer with a five-axis CNC router available in four main styles. replaced cables with chainflex in their application. The cables had to be able to withstand heavy duty applications, and at the same time possess a high degree of flexibility. The replacement cables have been in place over 10 years.

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chainflex® cables in concrete manufacturing

High-speed roller door

The igus® Micro flizz® cable carrier system delivers reliable power and data supply in compact spaces, even at extreme speeds up to 6 m/s and in temperatures as low as −40°F. Pre-assembled with energy chain, guide channel, and cables, it ensures smooth, quiet, and lubrication-free operation while withstanding millions of cycles. Ideal for roller doors, long-travel, and high-acceleration applications, Micro flizz® helps engineers achieve long service life with minimal maintenance and reduced downtime.

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chainflex in roller door application

Leather-Cutting Machine Success with igus® chainflex®

A furniture manufacturing plant faced recurring cable failures in its leather-cutting station. Despite continuous operation for 14-hour days, cables would fail every two months, causing up to a full day of downtime per incident. The company retrofitted the machine with chainflex® CF9 continuous-flex control cables, designed for extreme bending and compact installations.

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Leather-Cutting Machine Success with igus® chainflex®

Minimal Bend Radius In Stacking Unit

The igus® chainflex® CF98 control cable solved repeated breakdowns in automated phosphorous-screen stacking units—operating in just 0.7-inch (18 mm) bending radii and enduring 300,000 cycles per month in tight spaces—eliminating downtimes that previously cost over $9,300 annually. Pre-harnessed inside an igus® energy chain, the CF98 cable now delivers uninterrupted, long-term performance, enhancing both operational reliability and cost efficiency.

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Cable Carriers with a Longer lifetime

Robotic Cable Dress Packs

chainflex® robotic cables are built for multi-axis motion, handling ±180° torsion every 3 feet with millions of cycles. Dress pack solutions with triflex® energy chains keep cables secure, guided, and protected in demanding robot applications.
Reduce downtime and extend robot life with cables designed specifically for dynamic robotic environments.

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chainflex in robotic applications

Browse the Engineer's Toolbox

Frequently Asked Questions About Continuous Flex Cables

chainflex® cables are industrial-grade continuous flex motion cables designed for dynamic applications such as robotics, automation, and machinery. They are tested for millions of cycles and engineered to prevent cable failure in demanding environments.

Standard cables often fail under constant motion, leading to downtime and costly replacements. chainflex® continuous flex cables are designed with special materials and optimized stranding to withstand up to 2 billion test cycles, ensuring long service life and reliable signal transmission.

igus® offers a full range of continuous flex motion cables including control, data, servo, motor, bus, hybrid, fiber-optic, coaxial, robotic torsion cables, and pre-assembled readycable® solutions.

chainflex® cables come with a UL-verified guarantee of up to 4-year service life. This guarantee is based on testing in the world’s largest cable test lab of its kind, where cables undergo up to 2 billion cycles annually.

chainflex® continuous flex cables meet global standards including UL, CE, EAC, NFPA 79, and cleanroom ISO Class 1. They also support major communication protocols such as PROFINET, PROFIBUS, EtherCAT, and CC-Link.

By using specialized designs for continuous flexing, chainflex® cables minimize insulation cracks, conductor breaks, and EMI issues. This means fewer cable failures, less machine downtime, and higher production efficiency.

igus® offers robot cables specifically designed for 3D torsional motion with up to ±360° rotation per meter, making them ideal for multi-axis robots and automated machinery.

The chainflex CASE system reduces packaging waste, improves cable handling, lowers shipping costs by up to 84%, and allows easy reordering—supporting cost savings and greener logistics.

Yes. Depending on the cable type, they are available with oil-resistant, UV-stable, flame-retardant, and halogen-free materials, making them suitable for harsh industrial environments.

igus® provides free online tools including a service life calculator and cable configurator. These help you select the right cable and predict its performance in your specific application.

Yes. Engineers and purchasing managers can request a free cable sample box to evaluate product performance before committing to larger orders.

Hybrid cables combine servo power and feedback lines into a single continuous flex cable, reducing space, simplifying routing, and lowering installation costs—perfect for modern servo drive systems.

Yes. With the igus® readycable® service, continuous flex cables can be ordered pre-harnessed with connectors from brands like Siemens, Beckhoff, Allen Bradley, and SEW, ready for plug-and-play installation.

igus® offers more than 1,394 continuous flex cable types, available with no minimum order quantity. You can order by the foot (or meter), and most ship within 24 hours.

Contact Us

Questions or product information? Please contact:

gary johnson
Gary Johnson

chainflex Sales Manager

(416) 709-8448Contact an Expert

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