Custom Bimetallic Wire & Conductor Solutions

Design your high-performance composite conductors to exact application demands with FISSOT®. Rather than forcing your project into rigid factory templates, we enable engineering teams to define specific electrical conductivity, select from multiple bespoke insulation layers and custom plastic jackets, and adapt dimensions for specialized equipment. We strongly support small-batch testing and low-volume prototyping to validate your designs before scaling deployment.

Tailor-Made Conductor Materials

Copper-Clad Steel Conductor

Copper-Clad Steel Conductor

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Copper-Clad Aluminum Conductor

Copper-Clad Aluminum Conductor

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Nickel-Clad Copper Conductor

Nickel-Clad Copper Conductor

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Configurable Plating & Thermal Ratings

The matrix below reflects typical references. Every component—including nominal core diameter, cladding type, and volumetric ratios—can be adjusted to meet your specific target parameters.

Custom Gauge/Diameter Range Plating Options Tailored Coating Thickness Engineered Temp. Rating
0.90mm (Configurable)Nickel Clad Copper (NCC)5μm – 12μm (Adjustable)Up to 450°C
1.30mm (Configurable)Silver Plated Options17μm (Adjustable)Up to 200°C
1.80mm (Configurable)Tin Plated Options3μm (Adjustable)Up to 150°C
Engineering Simulation Tool

Bimetallic Wire Value Engineering Calculator

Evaluate your material configurations instantly. Input your custom technical specifications (diameter, target conductivity, core tensile strength) to run precision cost and weight optimization metrics against real-time copper prices.

Layer Customization

Bespoke Insulation & Outer Plastic Jacketing

To deliver an exact wire system integration, we provide fully flexible multi-layer extrusion profiles configured directly for your operational environment:

1. Tailored Insulation Layers:
Configure core protection using premium materials like high-purity Teflon (PTFE/FEP), flexible Silicone, or thermal-resistant cross-linked polymers.
2. Custom Plastic Jacketing:
Define external mechanical defense with custom-extruded layers of heavy-duty PVC, robust PE, elastomeric TPE, or high-abrasion TPU.
3. Specialized Material Features:
Engineered for specialized criteria: Flame Retardant, UV Resistant, Oil Resistant, or LSZH (Low Smoke Zero Halogen) profiles with precise RAL color matching.

Application-Specific Raw Materials

Your technical requirements dictate our material selection. We source targeted grades of high-purity oxygen-free copper and high-tensile steel or aluminum alloys to ensure electrical and mechanical precision from the foundation.

High-strength steel wire raw material High-purity copper belt raw material

Advanced Prototyping & Processing Infrastructure

Our manufacturing setups are built for structural adaptation, maintaining tight geometrical control whether running short pilot runs or continuous volume output.

FISSOT® Conductor Customization Equipment Custom Drawing and Cladding System Quality Control and Parameter Verification

Your Custom Development & Prototyping Roadmap

1

Defining Your Parameters

We work directly with your specifications. You define the precise electrical conductivity, tensile limits, composite alloy ratios (such as specific nickel-to-copper allocations), and overall cross-sectional configurations.

2

Small-Batch Testing & Prototyping

We actively support low-volume evaluation. Our setup allows agile pilot production, giving your engineering team the exact physical wire samples needed to perform early-stage bench tests with zero volume obligation.

3

Rigorous Performance Validation

Following small-batch fabrication, the prototype undergoes testing. We provide the physical test specimens alongside detailed laboratory data logs (resistance, elongation, cladding adhesion) for your formal approval.

4

Seamless Scale Integration

Once your R&D group validates the prototype performance data, we execute a seamless transition into full-scale delivery runs, matching the exact chemical and mechanical properties approved in step three.

5

Bespoke Packaging & Spool Configuration

We adapt to your winding and processing machinery. Custom spool types, specific inner diameters, target reel weights, and automated line-feed arrangements are tailored to integrate perfectly into your factory assembly systems.

Bespoke Packaging & Delivery Configurations

Protect material integrity and match your automated automated payoff systems with custom-selected spools, specific dimensions, and advanced transit protection.

Customized Conductor Pallet Arrangement

Bespoke Palletized Units

Tailored Spool Dimensions

Custom Reel Dimensions

Industrial Wooden Spool Protection

Anti-Oxidation Wrap

Hermetic Vacuum Packaging

Hermetic Vacuum Sealing

Engineering Criteria for Custom Inquiries

Because our production structures are fully adaptive, we engineer solutions far beyond basic off-the-shelf listings. To help our engineering team calculate precise sample evaluations and prototype pricing, please provide as much specification detail as possible:

For Customized Single Wire Designs

Specify your core and protective layer metrics:

  • Target core material and layer composition
  • Defined electrical conductivity & resistivity benchmarks
  • Outer plating type and custom thickness profile
  • Exact diameter or custom wire gauge bounds
  • Required elongation and tensile parameters
  • Custom insulation or outer plastic jacket options
  • Tailored packaging/spool dimensional requirements
  • Intended environmental application context

For Customized Stranded Configurations

Specify your internal geometric requirements:

  • Stranded wire layout and component distribution
  • Target conductivity and maximum resistance limits
  • Individual filament plating options & coating thickness
  • Overall strand diameter and single wire diameter bounds
  • Specific stranding pitch and structural lay direction
  • Conductor cross-sectional area requirements
  • Custom insulation or outer plastic jacket profiles
  • Bespoke packaging, reel weight, and spool specs

Product Customization FAQs

Can I define a specific electrical conductivity for my composite conductor order?
Yes, absolutely. FISSOT® specializes in custom-engineered bimetallic wires where you can specify precise cladding ratios, volume fractions, and material compositions to hit your exact electrical conductivity and resistance targets.
Do you support small-batch testing and low-volume prototyping for R&D?
We fully support your engineering and validation phases. You can initiate small-batch pilot runs to secure physical wire samples for your laboratory bench tests. This allows your team to verify mechanical and electrical compatibility before scaling up.
What choices do I have for custom core insulation and outer plastic jacketing?
We provide comprehensive multi-layer encapsulation profiles. For core dielectric protection, you can choose high-purity Teflon (PTFE/FEP) or Silicone. For the outer plastic jacket, we offer custom-extruded PVC, PE, TPE, or TPU with specialized characteristics like LSZH, oil, or UV resistance.
Can the packaging and spool configurations be tailored to match our automated winding machinery?
Yes. Packaging is handled as a fully customizable product element. You can define the spool raw material (plastic, heavy-duty metal, or wood), exact inner/outer reel dimensions, target traverse widths, and specialized protection like vacuum sealing or anti-oxidation wrap.
What technical criteria are required to generate a custom product design proposal?
To engineer the perfect conductor profile, please provide your target core-to-cladding metal choices, required wire gauge or outer diameter, target tensile strength, conductivity limits, layer specifications, and the intended operational temperature profile.
How do custom CCS, CCA, and NCC product profiles solve specific engineering challenges?
Custom composite configurations allow your system to capture dual material advantages:
  • Custom Copper-Clad Steel (CCS): Blends high-frequency electrical performance with maximum mechanical strength for grounding grids.
  • Custom Copper-Clad Aluminum (CCA): Engineered for massive, lightweight optimization in automotive wiring networks.
  • Custom Nickel Clad Copper (NCC): Tailored to deliver superior anti-corrosion properties and thermal survival up to 450°C in critical applications.

Certifications & Global Standards

As a technology-driven leader, FISSOT® actively shapes the industry by drafting international and national bimetallic wire standards.

ISO 14811 Standard
Core Authority

ISO 14811:2025

Primary Drafter of International Standard

National Standard

National Standard

Bimetallic Industry Development

JB/T Standard

JB/T 11868

Industrial Machinery Certification

Invention Patent

Invention Patent

Advanced Cladding & Welding Tech

ISO 14001

ISO 14001

Environmental Management System

ISO 9001

ISO 9001

Quality Management System

ISO 45001

ISO 45001

Occupational Health & Safety

Get Your Custom Manufacturing Quote

Fill out the form to get a detailed estimate within 24 hours. Our engineers are ready to assist you with your next big project.

  • Free Expert Consultation
  • Strict NDA Protection
  • Fast Prototyping

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