Custom PVC & Engineered Polymers Designed for Safety, Stability & Longevity
In electrical, electronics, and solar applications, material performance isn’t just a specification; it’s a safeguard. From wire and cable insulation to photovoltaic components, the compounds you choose must withstand thermal stress, resist degradation, and maintain dielectric integrity over decades of service. Our custom PVC formulations and engineered polymer compounds are developed to meet these exacting demands, delivering the flame retardancy, UV stability, and long-term durability that critical applications require. Whether you’re manufacturing high-voltage cable, consumer electronics housings, or solar panel components, we work with you to develop compounds tailored to your processing requirements, regulatory standards, and end-use environment.
Frequently Asked Questions Related to Electrical and Electronic Applications
What are the best plastics for cable insulation?
The best plastics for cable insulation depend on your specific application requirements. For standard electrical wiring, AuroraFlex flexible PVC compounds offer excellent dielectric strength with durometer ranges from 35A to 95A Shore A. For applications requiring enhanced fire safety, our low-smoke zero-halogen (LSZH) compounds minimize toxic fume generation. For industrial environments with chemical exposure, AuroraGuard CPE alloys provide superior oil and chemical resistance. Our technical team can help identify the optimal material based on your voltage, temperature, and environmental requirements.
What are the benefits of using PVC for wire insulation?
PVC compounds offer significant advantages for wire insulation including excellent dielectric strength for electrical isolation, inherent flame retardancy for fire safety, flexibility for easy installation, moisture resistance for wet environments, chemical resistance for industrial applications, and cost-effectiveness for high-volume production. PVC wire coating formulations can be customized with specific additives for enhanced UV stability, low-temperature flexibility, and flame retardancy to meet exact application requirements.
How do flame-retardant polymers improve cable safety?
Flame-retardant polymers improve cable safety by self-extinguishing when ignition sources are removed, preventing flame propagation along cable runs. Our compounds meet UL 94 and IEC 60332 standards for flame retardancy. Low-smoke formulations minimize visibility impairment and toxic fume generation during fire events. Low-smoke zero-halogen (LSZH) wire compounds are critical for transit, marine, data center, and building applications where occupant safety depends on reduced smoke toxicity.
What is low-smoke zero-halogen (LSZH) wire?
LSZH wire uses insulation and jacketing compounds that produce minimal smoke and no halogen gases when exposed to fire. Standard PVC releases hydrogen chloride and other corrosive gases when burned, which can damage equipment and endanger occupants. LSZH compounds eliminate these hazards, making them essential for enclosed spaces like aircraft, ships, trains, tunnels, data centers, and commercial buildings. Aurora’s LSZH formulations meet stringent fire safety requirements while maintaining excellent mechanical and electrical properties.
What is the difference between low-smoke and standard PVC compounds?
Standard PVC compounds may generate significant smoke and release halogen gases (hydrogen chloride) when burned. Low-smoke PVC formulations are engineered with specialized additives that reduce smoke generation during fire events. Low-smoke zero-halogen (LSZH) compounds go further by eliminating halogen content entirely, preventing corrosive and toxic gas release. The choice depends on fire safety requirements, installation environment, and regulatory compliance needs for your specific application.
Our compounds deliver superior insulation properties, exceptional flame resistance, and dimensional reliability across wide temperature ranges.
Whether your application involves high-voltage transmission, sensitive electronics, or outdoor solar installations, Aurora compounds provide the safety and durability that keep systems operating efficiently for years.
Our custom PVC and engineered thermoplastic compounds meet the critical safety standards governing solar, electrical, and electronics applications. We serve a wide range of needs; from flexible cable management systems and protective enclosures to structural panels and precision-molded components. Aurora’s technical team partners with you to deliver formulations tailored to your processing methods, performance targets, and application environments.
CASE STUDY
Setting a New Standard for Solar Enclosure Strength
“As a small business that focuses on innovating to solve pain points for installers and electricians, it’s important that we have a partner that collaborates and helps us problem solve. Aurora Material Solutions has been this partner in many ways, helping us pick the right material and validate the material. They’ve allowed us to create a competitive advantage in the market.”
Kyle Baum, President of EZ Solar
Electrical and Electronic Applications
Engineered Compounds for Electrical Infrastructure
Engineered Compounds for Electronics
Engineered Compounds for Energy Storage
Engineered Compounds for Umbilicals
Engineered Compounds for Wire and Cable
Engineered Compounds for Electronic Component Integration
Precision-Moldable Materials for Tight Tolerances & Heat Management
Aurora compounds used in electronic components provide high dielectric strength, flame resistance, and thermal stability. Ideal for connectors, circuit protection elements, and board-level housings, our polymers support miniaturization and automation in electronics assembly.
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Our Electrical and Electronics Solutions:
AuroraGuard™ PC (polycarbonate) compounds are amorphous, thermoplastics that possess outstanding impact strength, excellent colorability, and superior heat resistance with good electrical and thermal properties, low- temperature toughness, and superior dimensional stability. They can be provided unfilled or filled with specialized fillers, mineral or fiberglass reinforcement. PC compounds are available in flame-retardant grades (both non-halogenated and brominated), a wide range of melt viscosities, and can be offered with recyclable PC content and ultraviolet (UV) stabilized grades for outdoor weatherable applications. The polycarbonate (PC) product family complies with FDA (Food and Drug Administration), REACH (Registration, Evaluation, Authorization and Restriction of Chemicals), NSF (National Sanitation Foundation) and UL listed (UL 94).
AuroraGuard™ PC/ABS alloys provide impact strength, heat resistance, colorability, enhanced chemical resistance, very good aesthetics and dimensional stability. These compounds are also available in a recyclable grade series, which are filled with specialized fillers, minerals, or glass. These grades exhibit a superb combination of thermal and mechanical properties, excellent impact strength, high heat resistance, dimensional stability, great processability, flame retardancy, and a wide range of viscosities. AuroraGuard PC/ABS is often used for handheld scanners at checkout counters.
AuroraTec™ PC/PBT (polycarbonate/polybutylene terephthalate) compounds are made from alloys of amorphous polycarbonate and the semi-crystalline polybutylene terephthalate resin. They offer excellent chemical resistance, making AuroraTec PC/PBT ideal for electrical connectors located in harsh environments and outdoor connector boxes. Impact-modified AuroraTec PC/PBT grades can provide a high level of impact strength at low temperatures. There are also flame-retardant grades (both non-halogenated and brominated), glass filled grades, and UV stabilized grades.
AuroraGuard™ ABS (acrylonitrile butadiene styrene) combines the strength and rigidity of the acrylonitrile and styrene polymers with the toughness of the polybutadiene rubber, making them a great choice for electronic enclosures and computer keyboards.
AuroraGuard™ PBT (polybutylene terephthalate) is a high-performance engineering thermoplastic, classified as a semi-crystalline polyester. PBT exhibits outstanding chemical resistance, a very low shrink rate during molding, and excellent mechanical strength. It offers heat resistance up to 150°C, or up to 200°C when reinforced with glass fibers. In electrical applications, glass fiber-reinforced PBT is commonly used in connector materials, meeting stringent performance criteria such as UL 94 V0 flame retardance. This material also provides superior strength, toughness, low moisture absorption, and stable electrical and dimensional properties. Additionally, AuroraGuard™ PBT delivers excellent surface quality and luster, with no visible fiber floatation, making it ideal for both functional and aesthetic components in high-demand environments.
AuroraGuard™ PEI (polyetherimide) compounds start from the base resin, amorphous polyetherimide, which is an amber-to-transparent thermoplastic with characteristics similar to the related, much more costly plastic PEEK. Our PEI compounds are inherently flame resistant and provide a high resistance to elevated temperatures and solvents. Compounds within the AuroraGuard PEI family provide high mechanical property performance in continuous use environments to 340°F (170°C). Their toughness and rigidity can be further enhanced with fiberglass reinforcement.
AuroraTec™ PC/PET (polycarbonate/polyethylene terephthalate) alloys deliver exceptional mechanical, thermal, and chemical properties, making them highly suitable for a wide range of demanding military applications. These alloys offer superior durability and resistance to chemicals, weathering, and UV exposure, making them ideal for use in harsh operational environments. By combining the high-temperature resistance and dimensional stability of polycarbonate with the chemical resistance and toughness of PET, AuroraTec™ PC/PET alloys provide an optimal balance of strength and impact resistance. This makes them a preferred choice for electronic enclosures and housings, where structural integrity and reliability are paramount.
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Every application has unique performance requirements, processing parameters, and regulatory demands. Aurora’s technical sales team works directly with you to develop custom thermoplastic compounds tailored to your specific needs. Contact us today to discuss your project and discover how our engineered materials can solve your toughest formulation challenges.