Bondable wire is insulated wire treated chemically or mechanically to allow adhesion to materials like potting compounds or encapsulants.
Bondable wire typically uses PTFE insulation that has been surface-treated, most often through chemical etching, to increase its bondability. This treatment modifies the insulation’s outer surface, creating a texture that promotes adhesion to adhesives, potting compounds, or resins. The resulting interlock between materials provides added durability, ensuring that conductors remain sealed and stable under vibration, moisture, or chemical exposure. In commercial and industrial applications, bondable wire supports molded connectors, sealed enclosures, and overmolded assemblies, helping preserve long-term system integrity in harsh conditions.
Bondable wire is evaluated under standards from UL (Underwriters Laboratories), ASTM (American Society for Testing and Materials), and IEC (International Electrotechnical Commission) to verify performance and compatibility.
Bondable wire emerged with the adoption of fluoropolymer insulation in the mid-20th century. While PTFE insulation offered excellent thermal and electrical performance, its low surface energy made bonding difficult. Etching and surface modification techniques were introduced to enable reliable integration with encapsulated and sealed systems, expanding its use in demanding environments.