Case Study · Energy
US Smart Energy OEM: TC-ER Compliant 2AWG Power Cable Engineered
Engineering an inner- and outer-jacket material combination with the raw cable maker delivered a TC-ER compliant spec that hit the diameter and flexibility targets.
United States · 2025 · Energy harnesses
2AWG 3-conductor
TYPE TC-ER compliant jackets
Cleared for high-volume production
Background
A smart energy OEM in the United States required a custom power cable assembly with strict safety certifications for home electrification applications.
The Challenge
The 2AWG 3-conductor cable faced diameter and flexibility issues, and an initial material substitution — flame-retardant tape for the inner jacket — was rejected by the customer. It failed to meet the mandatory TYPE TC-ER certification required for both inner and outer jackets.
Our Solution
We collaborated directly with the raw cable manufacturer to engineer a compliant inner- and outer-jacket material combination. The combination met the TYPE TC-ER standard while achieving the target diameter and flexibility specifications.
The Result
We delivered a compliant technical specification that satisfied the customer's mechanical engineering team. The approval kept the project on its trajectory toward high-volume production.
Program Specifications
| Gauge | 2AWG, 3-conductor |
|---|---|
| Certification | TYPE TC-ER (inner + outer jacket) |