Leoni Cables Technical Services & Engineering Support

Specification to commissioning — expert cable engineering services for complex infrastructure projects.

Custom Cable Design

Our design engineering team develops application-specific cable constructions meeting precise electrical, mechanical, and environmental requirements. From concept to prototype in 15 business days.

Voltage Range 300V to 35 kV rated
Conductor Types Copper, tinned copper, aluminum
Temperature Range -60°C to +250°C operating
Prototype Lead Time 15 business days from design approval
Minimum Order From 500 meters (custom) / 100 meters (standard)
Custom cable design engineering

Engineering Process

01

Requirements Analysis

Application engineers review your project specifications — voltage, current, environment, standards, and mechanical constraints.

02

Cable Design & Simulation

Our design team models conductor sizing, insulation thickness, and shielding configuration using proprietary calculation tools validated to IEC standards.

03

Prototype & Validation Testing

Prototypes undergo full type testing in our ISO 17025 accredited laboratory — dielectric strength, insulation resistance, flame propagation, and mechanical endurance.

04

Production & Quality Assurance

100% online testing during production — electrical continuity, insulation resistance, and dimensional verification at every manufacturing stage.

05

Delivery & Technical Support

Complete documentation package — test certificates, datasheets, and installation guidance — accompanies every shipment. Post-delivery technical support included.

Service Scope & Applicability

Custom cable design services cover conductor sizes from 0.5 mm² to 630 mm² and voltage classes up to 35 kV. Designs requiring voltages above 35 kV (66 kV, 132 kV transmission class) fall outside our current manufacturing capability and are referred to specialist HV cable manufacturers. Minimum production runs for fully custom constructions start at 500 meters; orders below this threshold may incur additional tooling charges. Lead times for custom cables requiring third-party certification (UL, ATEX) extend to 8-12 weeks beyond standard prototype timelines due to external testing laboratory scheduling.

Additional Services

🔍

On-Site Cable Survey

Field assessment of existing cable infrastructure, routing evaluation, and upgrade recommendations for retrofit projects.

📈

Cable Sizing Calculation

Voltage drop, derating factor, and short-circuit current calculations per IEC 60364 or NEC for your specific installation conditions.

📝

Certification Assistance

Support for UL, CE, CCC, and ATEX certification processes — documentation preparation, sample submission coordination, and test witnessing.

Ready to Start Your Project?

Submit your cable requirements and our engineering team will respond within 24 hours with a preliminary specification.

Request Engineering Support