How do different types of cables compare in terms of conductivity and insulation?

Copper — the benchmark. With a conductivity of around 100% IACS, copper offers the best practical balance of electrical performance, mechanical strength, and workability. It solders easily, resists corrosion at connection points, and handles repeated bending well. That is why copper remains the default conductor for building wiring, appliance cords, and most fixed installations.

Aluminum — the lightweight alternative. Aluminum conducts roughly 61% as well as copper but weighs only about a third as much and costs significantly less per meter. It is the standard choice for overhead transmission lines and large cross-section distribution cables, where weight and material cost matter more than raw conductivity.

Tinned copper — the corrosion-resistant option. A thin tin coating shields the copper from oxidation and corrosion, making tinned conductors a sensible choice in humid or chemically aggressive environments.

PVC (polyvinyl chloride) — the everyday standard. PVC is cheap, tough, moisture-resistant, and easy to process, which is why it insulates the majority of low-voltage cables worldwide. Its continuous temperature rating is around 70°C. The catch is fire behavior: when PVC burns, it releases hydrogen chloride gas and dense smoke, which is why it is being phased out of high-occupancy buildings in many markets.

XLPE (cross-linked polyethylene) — the higher-performance upgrade. Cross-linking turns polyethylene into a thermoset that does not soften as temperatures rise, lifting the continuous rating to around 90°C. At the same conductor size, an XLPE-insulated cable can carry noticeably more current than a PVC equivalent. XLPE also has excellent dielectric properties, which makes it the standard insulation for medium- and high-voltage cables. It costs more than PVC, and because cross-linking is irreversible, offcuts cannot be recycled by simple remelting.

LSZH (low smoke zero halogen) — the safety-first choice. LSZH compounds release very little smoke and no halogen acid gases when exposed to fire. In tunnels, airports, data centers, and other enclosed or high-occupancy spaces, LSZH cables are often required by code because they dramatically improve the chances of safe evacuation.

Rubber and EPR — the flexible workhorses. Synthetic rubber insulation stays flexible across a wide temperature range and shrugs off ozone, UV, and weathering. Cables insulated with EPR are favored for mining, marine, welding, and other harsh environments where repeated flexing and outdoor exposure are the norm.

Silicone — the extreme-temperature specialist. Silicone insulation remains flexible from roughly −60°C to +180°C, which makes it the go-to for furnace wiring, heating elements, and aerospace applications. It is softer than most insulations and needs careful handling, but in high-heat settings it is often the only practical option.

PTFE — the chemical champion. PTFE resists essentially every acid, base, and solvent up to about 260°C. It is expensive and hard to process, so it is reserved for laboratory instruments, chemical plants, and other specialist uses.