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In the cable manufacturing industry, material selection and processing technology play decisive roles in determining product quality, performance, and cost efficiency. Among the most common insulation materials used today are silicone rubber and polyvinyl chloride (PVC). Each offers distinct advantages and limitations depending on the application environment, production scale, and performance requirements.
For manufacturers striving to meet demanding industrial or high-temperature applications, silicone cable extrusion has emerged as a preferred solution. Meanwhile, PVC extrusion remains dominant in consumer and general-purpose wiring due to its affordability and versatility.
This article provides a detailed comparison between silicone cable extrusion and PVC extrusion, helping engineers, production managers, and manufacturers understand their key differences—and how choosing the right technology can significantly impact performance and cost.
Since its establishment in 1998, Jinghan Machinery (Dongguan) Co., Ltd. has been dedicated to the design, R&D, and manufacturing of cable machinery equipment. Leveraging advanced Taiwanese technology and decades of innovation, Jinghan has become a trusted global supplier of high-end cable production systems, including precision Silicone Wire and Cable Extrusion Machinesdesigned for efficiency, quality, and energy savings.
1. Material Composition and Thermal Resistance
Silicone Rubber
Silicone rubber is a thermoset elastomer, meaning it undergoes an irreversible curing process that creates a three-dimensional molecular structure. This gives it excellent flexibility, electrical insulation, and heat resistance. Silicone cables can typically operate between -60°C and +250°C, making them ideal for high-temperature and outdoor applications.
PVC (Polyvinyl Chloride)
PVC is a thermoplastic compound, which softens when heated and hardens when cooled. It is widely used because of its low cost and easy processing. However, PVC insulation generally has a limited operating range of -20°C to +105°C, and prolonged exposure to heat can cause hardening, discoloration, or cracking.
Key takeaway: For high-temperature or demanding environments, silicone outperforms PVC in durability and thermal stability.
2. Flexibility and Mechanical Performance
Silicone Extrusion
Cables produced through silicone extrusion maintain exceptional flexibility even at low temperatures. This makes them suitable for applications requiring tight bending radii—such as robotics, aerospace wiring, and EV charging systems. Silicone also retains elasticity after aging, providing long service life.
PVC Extrusion
PVC cables are more rigid, especially in cold conditions. Although plasticizers can improve flexibility, they tend to migrate over time, leading to stiffness or cracking.
Silicone extrusion technology, using precision temperature control and high-quality dies, ensures consistent mechanical strength and elasticity, offering reliable performance across temperature extremes.
3. Electrical Insulation and Safety
Silicone Insulation
Silicone cables exhibit high dielectric strength, low surface conductivity, and excellent arc resistance. They are also non-toxic and flame-retardant, producing minimal smoke when exposed to fire.
PVC Insulation
PVC provides good insulation properties for general applications but releases toxic gases and heavy smoke when burned. For environments where safety and air quality are critical—such as hospitals, tunnels, or transportation systems—silicone is the superior choice.
Example: In aerospace and electric vehicle manufacturing, silicone insulation ensures both electrical reliability and safety compliance, even in extreme temperature conditions.
4. Processing Differences: Silicone vs. PVC Extrusion
Silicone Cable Extrusion Process
The Silicone Wire and Cable Extrusion Machineuses high-precision screws, multi-zone temperature control, and a curing system (typically hot air or infrared vulcanization) to produce crosslinked silicone insulation.
The process steps include:
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Material feeding and pre-heating
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Screw extrusion under controlled pressure
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Crosshead die shaping
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Continuous vulcanization (curing)
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Cooling, testing, and take-up
This method ensures superior consistency, thermal performance, and resistance to deformation.
PVC Extrusion Process
PVC extrusion involves melting PVC pellets and extruding them through a die under moderate temperatures (150–180°C). It is simpler and faster, but the resulting insulation is less heat-resistant and can degrade over time.
Comparison summary:
| Feature | Silicone Extrusion | PVC Extrusion |
|---|---|---|
| Type | Thermoset (vulcanized) | Thermoplastic |
| Temp. range | -60°C to +250°C | -20°C to +105°C |
| Flexibility | Excellent | Moderate |
| Flame resistance | High | Moderate |
| Cost | Higher | Lower |
| Durability | Very high | Limited |
5. Environmental and Chemical Resistance
Silicone cables resist ozone, UV light, moisture, and most chemicals, making them ideal for outdoor and industrial use. They maintain stability under oil exposure, radiation, and corrosive atmospheres.
PVC cables, while adequate for indoor or low-stress conditions, are more prone to degradation from sunlight and chemical exposure. They also contain chlorine, which raises environmental concerns during disposal or combustion.
In modern industries where sustainability and compliance are priorities, silicone cables offer a cleaner, longer-lasting solution.
6. Cost and Lifecycle Considerations
At first glance, silicone cable extrusion seems more expensive due to higher raw material costs and curing process complexity. However, long-term analysis often tells a different story.
Silicone cables offer:
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Longer service life (10–20 years in industrial use)
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Reduced maintenance and replacement costs
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Better performance under harsh conditions
PVC cables, while cheaper initially, may require frequent replacement, especially in heat-intensive applications, resulting in higher lifecycle costs.
Thus, for manufacturers focusing on total cost of ownership (TCO) rather than upfront price, silicone extrusion provides a better long-term return on investment.
7. Industrial Applications
| Industry | Preferred Insulation | Reason |
|---|---|---|
| Automotive (EVs) | Silicone | Heat & vibration resistance |
| Aerospace | Silicone | Lightweight, stable under pressure |
| Medical Devices | Silicone | Biocompatibility, sterilization safe |
| Consumer Electronics | PVC | Cost-effective for low-temp use |
| Construction | PVC | General wiring and lighting cables |
| Solar & Energy | Silicone | UV, ozone, and thermal resistance |
This clear distinction shows that silicone extrusion dominates in high-performance sectors, while PVC extrusion remains practical for cost-sensitive, general applications.
8. The Jinghan Machinery Advantage
Jinghan Machinery (Dongguan) Co., Ltd., founded in 1998, combines Taiwan’s proven engineering expertise with continuous innovation in extrusion, cabling, and stranding systems. The company holds dozens of national patents and serves as a benchmark in energy-efficient, intelligent cable manufacturing equipment.
Its Silicone Wire and Cable Extrusion Machine exemplifies cutting-edge engineering—featuring high-speed automation, precise temperature management, and optimized curing systems to produce consistent, high-quality cables for demanding industries.
Through sustainable design and smart controls, Jinghan Machinery empowers manufacturers to enhance efficiency, reduce waste, and maintain stable quality under all operating conditions.
To explore its advanced silicone extrusion solutions, visit:
Silicone Wire and Cable Extrusion Machine – Jinghan Machinery
Conclusion
When comparing silicone cable extrusion vs. PVC extrusion, the key differences lie in material performance, thermal stability, flexibility, and long-term reliability.
While PVC remains the economical choice for everyday wiring, silicone cable extrusion is essential for industries requiring superior performance under high-temperature or harsh conditions.
As technology advances and energy efficiency becomes a global priority, manufacturers are shifting toward smarter, sustainable, and high-precision production lines. With over 25 years of expertise, Jinghan Machinery (Dongguan) Co., Ltd. continues to lead this transformation—offering world-class extrusion machinery that balances innovation, quality, and environmental responsibility.
www.jinhanmachinery.com
Jinghan Machinery (Dongguan) Co., Ltd.
