Bowden Cables
Bowden cables - low-friction and durable. Individually assembled for you in the highest quality.
High-Quality Bowden Cable by Fortatech
Bowden cables are a simple and cost-effective solution for mechanical applications where forces must be transmitted through flexible cables. Since 1878, Fortatech has stood for the highest quality and innovation in the manufacture of Bowden cables and custom-made fine cables.
Whether in the automotive industry, in machine and equipment construction, in marine applications, or in agricultural technology – with our individually customized Bowden cables, we offer you a tailored solution for your specific application area.
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OPALTECH – The Innovative Technology for Your Bowden Cables
Bowden cables are a simple and cost-effective solution for mechanical applications where forces must be transmitted through flexible cables. Since 1878, Fortatech has stood for the highest quality and innovation in the manufacture of Bowden cables and custom-made fine cables.
Whether in the automotive industry, in machine and equipment construction, in marine applications, or in agricultural technology – with our individually customized Bowden cables, we offer you a tailored solution for your specific application area.
High-Quality Bowden Cable by Fortatech:
- Up to 10x longer lifespan – for sustainable and economic solutions
- Up to 3x lower pulling forces – for better ergonomics and higher comfort
- Smooth-running – for optimized applications with low force requirements
- Friction-optimized – for consistent performance throughout the entire lifespan
- Grease-free – for clean applications and less maintenance effort
In the diagram, you can see the comparison of pulling forces between standard Bowden cables and OPALTECH Bowden cables over their lifetime. The consistently low pulling forces of OPALTECH technology guarantee consistently high performance even after thousands of cycles.
Structure and Functioning of Bowden Cables
A Bowden cable consists of a wire rope that is routed in a flexible but pressure-resistant cable sheath. The cable sheath acts as a mechanical guide and forms the supporting unit of the Bowden cable.
Components of a Bowden Cable:
- Wire Rope (Core): Transmits pulling forces, various constructions available (spiral ropes, stranded cables)
- Cable Sheath: Guides the wire rope and ensures stability, e.g., flat wire spiral sleeves
- End Pieces/Fittings: Connecting elements to the components to be moved, individually adaptable
Choosing the right components is crucial for the optimal function and lifespan of the Bowden cable. Factors such as bending radius, expected load, and environmental conditions play an important role in configuration.
Detailed structure of a Bowden cable with components
Applications for Bowden cables
Our high-quality Bowden cables are used in a wide variety of industries and applications. Thanks to our decades of experience, we can offer the optimal solution for every application.
Automotive
Convertible tops
Rear parcel shelves
Sun blinds
Emergency releases
Loading lids
Child seats
Seat belt height adjustments
Window lifters
Door lock releases
Mirror adjustments
Handbrakes
Engine hoods
Air conditioning systems
Industry
Machine and apparatus construction
Shipbuilding / Engine construction
Vintage car market
Medical technology
Security technology
Agricultural vehicles
Elevator systems
Lighting
Sun protection
Wind power
Museums / Galleries / Theaters / Design
Custom manufacturing according to your requirements
Each application places specific requirements on a Bowden cable. We manufacture your Bowden cables individually according to your specifications and are happy to advise you on selecting the optimal components.
Available variants
- Cables: Spiral cables, stranded cables, with and without coating
- Cable housings: Flat wire spiral tubes, with and without inner lining, double block spiral tubes
- Fittings for cables: Pressed fittings (steel nipples, pull eyes, press-fit threads), loop connections, sprayed fittings
- Fittings for cable housings: End sleeves, tube casings, adjustment screws, locking sleeves
- Our technical experts support you in selecting the optimal components for your specific application. Contact us for personal consultation.
Further information on our product components:
Quality assurance through our own testing laboratory
At Fortatech, we place the highest value on the quality of our products. In our in-house testing laboratory, we conduct extensive tests to guarantee the performance and durability of our Bowden cables:
- Endurance tests: Simulation of real-world stresses over thousands of cycles
- Tensile tests: Determination of maximum load capacity
- Length measurements with SPC: Precise quality control during production
These comprehensive quality controls guarantee you the highest reliability and durability of our products even under demanding conditions.
Do you need customized Bowden cables for your application?
Our experts will be happy to advise you on the possibilities and work with you to develop the optimal solution for your specific requirements. Contact us today!
Frequently asked questions about Bowden cables
A Bowden cable can only transmit tensile forces, while a push-pull cable can transmit both tensile and compressive forces. For pure tension applications, Bowden cables are often the more cost-effective and simpler solution. Both Bowden cables and push-pull cables consist of an inner cable and a guide sheath, however, in push-pull cables, the inner core is specially stabilized to also transmit compressive forces.
The lifespan is significantly influenced by: the cable construction, the diameter of the deflection pulleys, the cable coating, the percentage load compared to the minimum breaking force, and the cable lubrication. With our OPALTECH technology, we can significantly extend the lifespan. The installation geometry also plays an important role - bend radii that are too tight can significantly reduce the lifespan. For stranded cables, a pulley diameter of at least 25-42× the cable diameter is recommended.
The minimum bending radii depend on the cable construction. For stranded ropes with construction 6x7-WSC, we recommend a pulley diameter of at least 42x the rope diameter, for 6x19-WSC at least 25x the rope diameter. Spiral ropes are generally not suitable for redirections. If the bending radii are too tight, the resistance when operating the Bowden cable increases considerably and the service life is greatly reduced. For push-pull cables, even larger bending radii are recommended.
As standard, we offer wire ropes made of galvanized steel or stainless steel (1.4301 / 1.4401). For special requirements, other materials can also be processed. The cable housings are typically available in steel with plastic coating made of PE or PVC. Depending on the application area and environmental conditions (e.g., corrosive environments, high temperatures), special versions with special coating or from special materials can be manufactured. For outdoor use or near seawater, we recommend our marine special versions.
The OPALTECH technology offers up to 10x longer service life, up to 3x lower pulling forces over the entire service life, smooth operation, friction-optimized movement, and operates without grease lubrication. This results in consistent performance throughout the entire service life of the Bowden cable. The special coating also prevents drying out, which often leads to breakage in conventional solutions. Our tests show that OPALTECH Bowden cables still exhibit nearly the same actuation forces after 50,000 cycles as they did at the beginning, while conventional systems show significant signs of wear.
Linka Bowdena składa się z elastycznej linki wewnętrznej, która jest prowadzona w elastycznej, ale sztywnej w kierunku nacisku osłonie. Zasada opiera się na tym, że siły ciągnące mogą być przenoszone na dłuższe odległości i wokół zakrętów. Gdy jeden koniec linki jest pociągany, linka porusza się wewnątrz osłony i przenosi siłę ciągnącą na drugi koniec. Osłona pozostaje przy tym nieruchoma i służy jako prowadnica i przeciwłożysko. Umożliwia to przenoszenie siły przez elastyczne ścieżki, co jest szczególnie korzystne w ruchomych konstrukcjach lub w przypadku ograniczonej przestrzeni.
Conventional Bowden cables require regular lubrication to minimize friction between the cable and housing and to increase service life. In case of heavy soiling, cleaning and relubrication may be necessary. Our OPALTECH Bowden cables, on the other hand, require significantly less maintenance as they work grease-free thanks to their special coating while still providing optimal gliding. Generally, Bowden cables should be regularly checked for damage, kinks, or corrosion. At the first signs of increased resistance or uneven operation, we recommend maintenance or replacement of the Bowden cable.
Yes, Bowden cables can be specially adapted for extreme environmental conditions. For high temperatures, we offer versions with heat-resistant materials that withstand temperatures up to 200°C. For corrosive environments, we recommend stainless steel cables and special coatings. We also have special, corrosion-resistant versions for use in environments with high humidity or salt water (marine applications). For extreme cold, special lubricants and materials are available that function reliably even at sub-zero temperatures. For extreme requirements, we would be happy to advise you on the optimal solution for your application.
The correct dimensioning of a Bowden cable depends on several factors:
- Force to be transmitted: The higher the force, the stronger the cable must be dimensioned
- Routing/geometry: Many tight curves require more flexible, thinner cables
- Actuation distance: Longer distances often require more stable constructions
- Environmental conditions: Extreme conditions require special materials
- Service life requirements: Higher requirements require stronger dimensioning
For correct installation of a Bowden cable, the following points should be observed:
- Plan the routing: Avoid tight bending radii and sharp kinks
- Define fixing points for the housing: The housing must be fixed at both ends
- Provide sufficient length: The Bowden cable should not be mounted under tension
- Ensure correct connection with the connecting components
- Do not cause damage to the cable or housing during installation
- Lubricate if necessary (except for OPALTECH technology)
For Bowden cables, we offer a variety of fittings for cables and cable housings:
Fittings for cables:
Fittings for cables:
- Pressed steel nipples in various shapes (A and B)
- Pull eyes in different versions
- Press-on threads with different thread sizes
- Pull brackets for special applications
- Loop connections with or without thimble
- Injection-molded fittings (nipples, cross nipples, balls, pull eyes)
- Special plastic fittings for specific requirements
- End sleeves for fixing and sealing
- Attachment hose sockets in various designs
- Threaded hose sockets with different thread sizes
- Adjustment screws for fine-tuning
- Locking sleeves for movable applications
- Couplings with grease nipples for easy maintenance
Bowden cables are basically well suited for use in environments with vibrations. The flexible construction of the Bowden cable can absorb vibrations to a certain extent. However, strong, continuous vibrations over a longer period can lead to increased wear, especially at the contact points between cable and housing. For applications with strong vibrations, we recommend:
- Use of coated cables that reduce wear
- Regular lubrication (except for OPALTECH technology)
- Generous dimensioning of the Bowden cable
- Firm fixation of the housing at several points
- Avoidance of resonance frequencies through appropriate routing
Typical problems with Bowden cables and their solutions:
- Increased resistance/stiffness: Usually caused by contamination, lack of lubrication, or too tight bending radii. Solution: cleaning, lubrication, checking the routing.
- Breakage of the inner cable: Can be caused by overload, material fatigue, or corrosion. Solution: replacement of the Bowden cable, possibly with stronger dimensioning.
- Damage to the housing: Often due to external influences or too tight bending radii. Solution: replacement of the Bowden cable, better routing, possibly protective measures.
- Tearing out of the end fitting: Can happen with overload or incorrect installation. Solution: replacement with correctly dimensioned fitting, professional installation.
- Corrosion: Especially in humid or aggressive environments. Solution: use of corrosion-resistant materials, regular maintenance.
Bowden cables can basically be used in safety-relevant applications, however, special requirements must be observed. For safety-critical applications, we recommend:
- Significantly higher safety factors in dimensioning (factor 10 or higher)
- Redundant systems wherever possible
- Regular maintenance and inspection
- Documented testing processes and acceptances
- Use of certified components where required
The maximum practical length of a Bowden cable depends on several factors, including the diameter of the cable, the quality of the components, and the specific application. For standard applications, the recommended maximum length is about 3-5 meters. For longer distances, the frictional resistance increases significantly, leading to higher actuating forces and faster wear.
However, with our OPALTECH technology, longer Bowden cables can be realized as the friction-optimized design requires significantly lower actuating forces. In special applications, we have already implemented Bowden cables with lengths of over 10 meters. For very long distances, we recommend consulting our experts to find the optimal solution for your requirements.
However, with our OPALTECH technology, longer Bowden cables can be realized as the friction-optimized design requires significantly lower actuating forces. In special applications, we have already implemented Bowden cables with lengths of over 10 meters. For very long distances, we recommend consulting our experts to find the optimal solution for your requirements.