BWE Ltd is a British engineering company specialising in continuous extrusion machines and cold pressure welders, supporting manufacturers across the non-ferrous, cable and tube industries.
With increasing demand for reliable, efficient and high-performance manufacturing processes, continuous extrusion technologies continue to play an important role in the development of advanced cable and conductor solutions. BWE’s Conform™ and Conklad™ technologies are established solutions used across a range of applications within these industries.
Conform™ Continuous Rotary Extrusion (CRE) technology is used for applications including copper and aluminium rectangular wire, such as magnet wire for transformers, solid aluminium conductors for cable applications, copper busbars, trolley wire and other shaped conductors. The technology is also suitable for round refrigeration tube and multiport or PFC tubes in different alloys.
Conklad™ technology is designed for applications including ASC wire, OPGW, sheathed composite cores and other products requiring a seamless aluminium sheath or non-ferrous cladding.
Advancing Aluminium Sheathing for High-Voltage Cables
BWE’s SheathEx™ technology was first developed in 2005 and has since become an established method for the seamless aluminium sheathing of high-voltage cables.
Previously, all SheathEx lines supplied globally were designed for corrugated aluminium sheathing. This proven and reliable process uses two 12.0 mm diameter aluminium rods to produce a continuous aluminium sheath.
BWE has now developed a SheathEx line capable of producing both corrugated and smooth aluminium sheaths. One of the first SheathEx customers worked closely with BWE to develop and convert their existing line for both applications. Extensive testing, carried out alongside their plastic extrusion process, demonstrated that the cable could be bent and wound onto a drum without kinking or damaging the aluminium sheath.
Existing customers can also retrofit their corrugated SheathEx lines with this new capability.
The SheathEx process provides a continuous, seamless aluminium sheath without welds. The resulting sheath offers excellent conductivity, strong environmental performance, low weight and proven reliability. By using standard CCR aluminium rod, the process provides a cost-effective solution for the sheathing of medium, high and extra-high voltage power cables.
Supporting Future Applications
BWE continues to develop new products and applications across emerging technologies, including Wire Arc Additive Manufacturing (WAAM), 3D printing, electric vehicles and precious metals.
Proving trials and demonstrations are available at BWE’s headquarters in Ashford, Kent, England. The company’s research and development department works with customers to assess, review and validate new applications before machine investment.
Alongside its extrusion technologies, BWE also manufactures and supplies a complete range of cold welders and dies, providing fast, cost-effective and reliable solutions for welding non-ferrous materials, from fine wire through to round rod.
™ SheathEx, Conform and Conklad are registered trade marks of BWE Ltd.
