Automotive Cable Protection: Sleeving, Tubing & Shielding Solutions
Electrical systems are becoming more advanced, with electrical complexity, higher operating voltages, and demanding environments. Automotive cable protection, like wire sleeving and heat shrink tubing, plays a critical role in maintaining system integrity, protecting electrical connections from abrasion, fluid, and electromagnetic interference (EMI), while ensuring safety, longevity, and compliance.
Here we outline the primary types of automotive wire protection and provide guidance on selecting the right one for your application.
Why Automotive Cable Protection Matters
Vehicle wiring systems are subject to harsh operating environments: elevated temperatures, continuous vibration, chemical exposure, and mechanical wear. Unprotected wires are prone to abrasion, short circuits, signal interference, and premature failure. With many vehicle components being connected, if one connection becomes damaged from one of these risks, the entire vehicle can be impacted.
If you’re unfamiliar with the different primary wire types used in these systems, explore our Automotive Primary Wire Overview for a breakdown of standard constructions, insulation materials, and voltage ratings.
Key protection goals to consider for smooth operations include:
- Preventing damage from abrasion and vibration
- Resisting fluids (oil, fuel, saltwater, coolant)
- Managing EMI in data-heavy systems
- Organizing and bundling cable runs for efficient assembly and maintenance
- Ensuring compliance with regional and OEM standards
Vehicle applications can also differ:
- Under-hood environments require high heat resistance
- Interior harnesses need low-profile, flexible protection
- Battery and charging systems demand high-voltage shielding
Next, we’ll break down the different cable protection solutions.
Types of Automotive Cable Protection
1. Cable Sleeving
Cable Sleeving offers abrasion protection and cable bundling in a lightweight, flexible form. Common types include:
- Braided Sleeving: Expands to fit over connectors and is great for dynamic applications. Varieties include coated, metal and shielding, expandable, and non-expandable.
- Wrap-Around Sleeving: Ideal for retrofit or repair and easy to install after cables and wires are already in place.
2. Heat Shrink Tubing
This type of tubing is an essential component in automotive cable protection, offering both identification and insulation benefits, with color coding capabilities and increased wire and cable protection from abrasion, moisture, debris, and strain.
Typical Uses: Wire insulation, cable bundling, strain relief, environmental sealing, electrical repairs, and EV & hybrid vehicles.
3. Non-Shrink Tubing
Non-shrink tubing provides insulation and routing protection without the need for heat application. It is often used in applications where heat shrink is impractical due to heat-sensitive components or the need for removability.
4. Convoluted Tubing
Convoluted Tubing, also known as loom, provides mechanical protection and routing support for wiring in high-vibration and high-abrasion environments. The ribbed design allows flexibility while maintaining crush resistance, making it ideal for under-hood and chassis applications.
Common varieties include slit and non-slit versions for easy installation and wire access. Many of these products are made from thermoplastic tubing such as nylon or polyolefin.
5. Spiral Wrap
Spiral wrap is a flexible, re-openable cable management option that allows for easy wire breakout along the length of the run. It bundles wires together while still enabling inspection or repair without removal.
| Protection Type | Temp Range | Application | Typical Material |
|---|---|---|---|
| Expandable Sleeving | -50°C to 150°C | Bundling, abrasion | PET, Nylon |
| Non-Expandable Sleeving | -70°C to 200°C | Durable abrasion protection | Silicone rubber, fiberglass |
| Coated Sleeving | -60°C to 320°C | High-temp abrasion resistance | Acrylic, Fiberglass |
| Heat Shrink Tubing | -55°C to 125°C | Sealing, insulation, and strain relief | Polyolefin, PVC, Teflon |
| Non-Shrink Tubing | -270°C to 260°C | Routing, crush protection | PVC, TFE, FEP |
| Slit Convoluted Tubing | -40°C to 125°C | Routing, abrasion resistance, retrofit access | Nylon, PE, FR-PP |
| Non-Slit Convoluting Tubing | -40°C to 125°C | Routing, sealed protection | Asphalt Coat Cotton/Polyester, Nylon |
| Spiral Wrap | -60°C to 80°C | Abrasion protection, wire breakouts | Nylon, PE |
How to Choose the Right Automotive Cable Protection
When selecting automotive cable protection and management solutions, consider the following:
- Operating Temperature: Match protection to heat zones (e.g., underhood vs. interior)
- Abrasion Risk: Sleeving or conduit for exposed routing
- Fluid Exposure: Select materials resistant to oil, fuel, and coolant
- Space Constraints: Use thin-wall tubing or flexible sleeving for tight installs
Emerging Trends in Cable Protection for EVs
As electric and hybrid vehicles are emerging, they introduce new challenges and the growing importance of wire and cable protection to allow for long-term reliability.
- High-voltage cables (orange) must be resistant to heat and EMI
- Battery wiring requires lightweight but highly protective sleeving
- Thermal events demand flame retardant or non-meltable materials
- ISO 15118 & CAN-FD systems increase shielding importance
Automotive cable protection is essential for building reliable, safe, and efficient vehicles. Proper cable protection helps ensure abrasion resistance and long-term electrical reliability. If you have any questions about selecting the right solution for your automotive application, please reach out. We can help you find the best answer for your cable protection needs.