Nano-Dies Enable Dramatic Copper and Aluminium Savings in Power Cable Manufacture

Here is a simple test that any cable manufacturer can perform with ease. Measure the temperature at output of the final compacting die, using an infrared thermometer. Then change to a Nano-Die of exactly the same bore diameter and repeat the test. A major cable company in Malaysia recently performed this test. Results:
PCD die: 46° C
Nano-Die: 40° C

Nano-Dies run cooler because they have lower friction than other dies. So, they do less damage to the microstructure of the conductors during the compacting process. This results in significantly lower electrical resistance in the cable conductors. Hence, conductors may be lightened while maintaining fully compliant cable.

2% Cu or Al savings are easily achievable using Nano-Dies to replace PCD compacting and stranding dies.

If you are replacing Tungsten carbide compacting dies, the savings are considerably higher.

These savings are highly significant. For example, if you are currently using $10M worth of Copper and Aluminium per month and you save 2% of that material, you just saved $200,000 per month.