Understanding UL Wire Options that Surpass Industry Standards

UL is among the most important third-party agencies in the world, helping define global safety standards for a wide range of products and industries. Whether it is automotive, oil and gas, or plastics manufacturing, UL has established standards that are the cornerstone for numerous global product safety regulations.

For new products that require a custom cable assembly, navigating the precise UL requirements that apply can be confusing.
In this webinar, we will cover how UL and non-UL wire options can benefit your custom cable assembly build, helping get your product to market faster for less costs.

For more information on our custom cable assemblies solutions, visit https://www.epectec.com/cable-assemblies/.

1. Understanding UL Wire Options That Surpass Industry Standards 10.16.2025

2. Agenda Understanding UL Requirements for Bulk Wire How UL Wire is Manufactured Common UL-Rated Wire Options Options for Custom Designs - UL & NON-UL Getting Started With Your Custom Build

3. Understanding UL Requirements for Bulk Wire

4. Custom Cable Assemblies & Wire Harnesses UL Hook-Up Wire Heavy Gauge Cables Custom Overmolded Cables Medical Cables RF Coaxial Cable Splices D-Sub (9, 15, 25, etc.) Circular & Metal Connectors Power and Ribbon Cables RJ45 (CAT5E & 6), RJXX

5. Automated Equipment Automated Wire Stripping Automated Cut-To-Length, Wire Stripping, and Simple Termination Automated Termination and Circuit Identification Fully Automated Electric Testing

6. In-House Wire & Conductor Capabilities UL-Approved Wire-Single UL1007/1569, UL1015 UL1061 Many others UL-Approved Wire-Multi UL2464, UL2517 UL2651 Flat Cable Many others Conductor Materials Bare Copper Tinned Copper Conductor Size 4 AWG to 40 AWG Strand Types Solid Stranded High Strand Count Shielding Braided Tinned Copper Foil Shield Shield + Drain Wire

7. Cable Anatomy - UL Approvals #2 Overmold *Flame Rated* #4 Crimp Terminal #1 Bulk Wire *UL RATED* #3 Connector *Flame Rated*

8. 1) 2) 3) 4) Brand Name UL Wire vs. Equivalent UL Wire “Typical for manufacturing quantities of 1,000 pcs. or higher.” BRAND NAME WIRE BRAND NAME CONNECTOR BRAND NAME WIRE EQUIVALENT CONNECTOR EQUIVALENT WIRE EQUIVALENT CONNECTOR EQUIVALENT WIRE BRAND NAME CONNECTOR

9. How UL Wire is Manufactured

10. UL Approved - Bulk Wire Single conductor and multiconductor wires are extruded with UL approval

11. Cable Anatomy - Printed UL Marking UL Rated Wire Must Have Printed Markings to Comply with UL Requirements AWM or UL Spec Temperature Voltage Flame Rating

12. Common UL-Rated Wire Options

13. UL-Approved Bulk Wire

14. UL-Approved Power Cables UL-Approved Power Cables in 16 weeks & $30K NRE UL Can Apply to the Completed Cable Assembly UL Approval Applies to a Specific: Manufacturer Material Type Connector Type No other changes are permitted

15. Typical Equivalent UL Wire Options “ Internal Wiring of Appliances” Extremely common Hook-up wire Single-conductor Multi-conductor Flammability Ratings are Critical Shielding Options Braided shield Metalized foil Drain wire Specifications Voltage Temperature Jacket Thickness Shielding Flammability UL Materials PVC XLPE PTFE FEP Silicone

16. UL1007/UL1569 Single Conductor Wire Single Conductor Wire Material: PVC Voltage: 300VAC UL1007: 80°C UL1569: 105°C Flame Rating: Horizontal Flame Appliance Wiring Material UL 758 Wire is Dual Certified to Both UL1007 and UL1569

17. UL2464 Multiconductor Wire Multiconductor Wire Material: PVC Voltage: 300VAC Temp: 80°C Flame Rating: VW-1 Cable Flame Appliance Wiring Material UL 758 UL2464 is the Multiconductor Version of UL1007/1569

18. UL1015 Single Conductor Wire Single Conductor Wire Material: PVC Voltage: 600VAC Temp: 105 ° C Flame Rating: Horizontal Flame Appliance Wiring Material UL 758 UL1015 is Most Commonly Used in Ground Wires and Bonding Connections

19. UL2517 Multiconductor Wire Multiconductor Wire Material: PVC Voltage: 600VAC Temp: 105 ° C Flame Rating: VW-1 Cable Flame Appliance Wiring Material UL 758 UL2517 is the Multiconductor Version of UL1015

20. UL2651 Ribbon Cable Flat Cable, Ribbon Cable Material: PVC Voltage: 300VAC Temp: 60 ° C Flame Rating: Horizontal Flame Appliance Wiring Material UL 758 UL2651 Covers 16AWG Through 26AWG Configurations

21. Additional UL Wires UL1061: SRPVC, 80 ° C, 300VAC UL3271: XLPE, 125 ° C, 600VAC UL3239: Silicone, 200 ° C, 60KVDC UL1180: PTFE, 200 ° C, 300VAC UL1330: FEP, 200 ° C, 600VAC UL1332: FEP, 200 ° C, 300VAC Appliance Wiring Material UL 758 Numerous UL Ratings Overlap One Another’s Performance

22. Service Cords & Power Cables SOOW/SJOOW SEOOW/SJEOOW STO/STOW SVT/SJT 300V/600V Jacket Material: TPE Thermoplastic Elastomer Temps -50 °C to 105 °C Resistance to: Oil, ozone, moisture, and abrasion UL Flexible Cord - UL 62

23. Mil Spec to UL Equivalent The U.S. Military Has Assigned Mil-Specs to Common UL Wires Many Projects Over-Specify Wire Requirements When a Standard UL Wire Type is Sufficient UL1015 is an Equivalent to M16878/1 - Type B Single conductor Stranded tinned copper wire PVC Polyvinyl Chloride insulation 600V rated 105°C max temperature

24. Options for Custom Designs - UL & NON-UL

25. Minimum Voltage and Temperature Requirements UL Listing Jacket Material

26. Custom Extrusion Options Using UL Wire Low Cost Not available “off-the-shelf” Must meet minimum order quantity Complete Customization +50 conductor cross-sections Mix and match wire sizes Vary the shielding Maintaining UL Compliance Some customization may violate UL “We Extrude Our Own Wire in About 3 Weeks”

27. “Can you make a plain wire jacket with no markings? Biocompatibility - must be non-UL Connectors made with TPU overmold materials Bulk wire made with TPU wire jacket materials Anything that violates UL requirements … NON-UL NON-UL Wire Options Customer Requested Changes that Violate UL Requirements

28. Getting Started With Your Custom Build

29. Taking the Design First Steps What Industry and Agency Approvals? Where Will This be Sold? Globally recognized Additional testing required for Korea, Taiwan, South Africa, Chile, and Argentina Initial Certification Product safety Environmental qualification Establish System Requirements

30. Epec Inquiry Form When starting a project with Epec, we ask if you could please fill out our Inquiry Form This allows us to capture all the information of your design upfront, eliminating guess work Also allows us to provide you with an accurate quote

31. Summary

32. Summary There are dozens of existing UL spec wires that may work in your application Most name-brand, hook-up wire carries an existing UL rating UL-rated wires can be customized, such that the changes don’t violate UL Omitting wire markings or biocompatibility can violate UL ratings UL-rated terminated cables are available, but may incur additional UL testing

33. Our Products Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards CNC Machining User Interfaces Flexible Heaters EC Fans & Motors

34. Q&A Questions? Enter any questions you may have in the control panel If we don’t have time to get to it, we will reply via email

35. Thank You Check out our website at www.epectec.com . For more information email [email protected] . Stay Connected with Epec Engineered Technologies Follow us on our social media sites for continuous technical updates and information: