What are EV charging cables made of?

p> Author:evcome-Ev Charging Stations Manufacturer

Electric vehicles (EVs) are becoming increasingly popular as a cleaner and more environmentally friendly mode of transportation. One of the most crucial components of an EV is the charging cable. But have you ever wondered what EV charging cables are made of? In this article, we will dive deeper into the composition of these essential cables.

What are EV charging cables made of?

EV charging cables are typically made of three main components: the conductor, the insulation, and the jacket. Each component serves a unique purpose in ensuring the safety and efficiency of the charging process.


The conductor is the core of the charging cable and is responsible for carrying the electrical current from the charging station to the EV's battery. Copper is the most commonly used material for the conductor in EV charging cables due to its low resistance and high conductivity. However, copper is also relatively heavy and expensive, prompting some manufacturers to explore alternatives such as aluminum or silver.


Insulation is an essential aspect of EV charging cables as it acts as a barrier between the conductor and the outside environment, protecting users from electrical shock and preventing any electrical leakage. The most common materials used for insulation are polyethylene and polypropylene, both of which offer excellent electrical insulation properties while being flexible enough to allow for easy bending and coiling.


The jacket is the outer layer of EV charging cables that provides a protective barrier against abrasions, chemical exposure, and extreme temperatures. Commonly used materials for jacket construction include PVC, thermoplastic elastomers, and rubber. The choice of jacket material depends on the intended use of the cable, such as outdoor versus indoor charging, and the environmental conditions it will be exposed to.

Types of EV charging cables:

There are two main types of EV charging cables, alternating current (AC) and direct current (DC) cables. AC cables are typically used for slower charging situations, such as overnight charging at home or in a workplace parking lot. AC cables use a Type 1, also known as J1772 connector or a Type 2, also known as Mennekes connector.

In contrast, DC cables are used for rapid charging situations, where a large amount of energy needs to be delivered in a short amount of time. DC cables use a CHAdeMO and Combined Charging System (CCS) connector. These connectors are capable of delivering high power to the vehicle's battery, enabling it to charge up to 80% in as little as thirty minutes.

Maintenance and care of EV charging cables:

Like any other piece of equipment, EV charging cables require proper maintenance and care to function effectively, and without interruption. Here are some tips to keep your EV charging cable in excellent condition:

Regularly clean the cable's connectors, terminals, and pins with a soft cloth and a mild cleaning solution.

Avoid kinking or bending the cable excessively, as it can cause damage to both the insulation and the conductor.

Store the cable in a dry, cool place, free from exposure to direct sunlight, heat, or extreme weather conditions.

Inspect the cable regularly for any signs of wear or damage; if any damage is found, immediately replace the cable to avoid potential safety hazards.


Electric vehicle charging cables are an essential component of EV charging infrastructure. Understanding the composition and functionality of these cables can help users make informed decisions when choosing an EV charging cable that best fits their needs. Whether you are a daily commuter or a long-distance traveler, always prioritize safety and proper maintenance to ensure a smooth, hassle-free charging experience.



Ev Charging Stations Manufacturer

Ev Charger Factory

Wallbox EV Charger

Portable EV Charger manufacturers

DC EV Charger manufacturers

Ev Charging Cable Manufacturers

Just tell us your requirements, we can do more than you can imagine.
Send your inquiry
Chat with Us

Send your inquiry

Choose a different language
Current language:English