Cables and splitters for harsh welding environments

Illustration of robotic welding machine in action

Protected from weld spatter by TPE jackets and silicone tubes

In a welding environment, a cordset’s life span can be short. Weld spatter can burn through the cable, or the accumulated weight of weld debris can pull the cable out of the overmold. Balluff offers cables with Thermoplastic Elastomer (TPE) jackets, which offer weld spark resistance and a high flex life rating (>10 million cycles).

Then Balluff adds a silicone tube over the TPE cable and molds the tube into the connector. This creates an insulating air pocket that gives the cordset an even higher temperature resistance. The silicone tube also prevents occasional weld spatter and sparks from burning through the cable. The cable’s locking nut is coated with PTFE, preventing spatter buildup that can make it impossible to disconnect a damaged cordset.

Cordsets need protection near the sensor, but I/O blocks mounted in a weld area need protected cables as well. All Balluff I/O blocks have dual I/O on each port. To access both I/O you need a splitter to break out the two separate legs. Balluff’s new splitter cables offer the same TPE jackets with added silicone tubes molded into the connectors. Now you can fully utilize I/O blocks and protect cables where they are vulnerable, reducing downtime due to cable failure.


  • Operating temperature (fixed) -60…250 ºC
  • Air inside silicone tube insulates the cable
  • Silicone tube overmolded into the head to prevent ingress
  • Resistant to thermal shocks
  • PTFE coated nut prevents debris from sticking
  • Cable lengths from 0.3 m…2.0 m;
    splitter lengths from 0.3 m…1.0 m