Bespoke Products

Expert help and advice

The Ellis Innovation Hub brings together a wealth of knowledge and experience relating to cable management and short-circuit restraint, combined with manufacturing capability. This capability is at your disposal to solve technical challenges and develop new innovative products.

Our dedicated team of project and mechanical design engineers can help with any more challenging questions. We love a challenge, so if you have a particular issue regarding the cleating or containment of electrical cables, we would be happy to find a solution for you.

DEFINE

We meet with you to fully define your engineering challenge. We use our wealth of knowledge and experience in cable management and short circuit restraint to explore potential solutions with you.

DEVELOP

We develop those solutions in 3D CAD design software. This allows us to create a precise and realistic representation of your new product.

REFINE

We refine the solution with precise calculations and replicating usage using FEA analysis. This ensures that your new product is safe, reliable, and meets your performance requirements.

PROTOTYPE

We build a full-scale working prototype of your new product. This allows us to validate it in real-world conditions and make any necessary adjustments.

TEST

We subject your prototype to extensive testing to ensure its quality and performance. This testing includes tensile, axial & lateral load, impact, needle flame, UV & short-circuit testing. As well as testing for extreme temperatues (-80 to +120°C).

MANUFACTURE

Once your product has been approved, we develop a detailed manufacturing process to ensure that it is produced efficiently and to the highest quality standards.

Case Studies

The following case studies demonstrate some of the examples where Ellis' innovation has provided the perfect cable management solution.

Siemens Helwin 2 Offshore Windfarm

The requirement was to feed seven 117mm diameter cables along a specified route within a fabricated structure, which featured a significant number of twists and turns. The problem was that there was no existing product that would enable the cables to be installed in an efficient, safe and cost-effective manner.

Bespoke Cable Hangers for Train Tunnel Application

Ellis were approached by a customer to supply cable hangers for a rail project. Cable hangers are standard products for Ellis and we carry a wide range in stock. We can also offer bespoke solutions which are designed and fabricated entirely in the UK.

Bespoke Cable Hangers for Topside of Mine

Ellis were contacted by a mine in North Yorkshire. During the early stages of the project Ellis were asked to provide a solution to supporting power cables around the site. The challenge was to provide a large number of parts in a short timescale.

Bespoke Cable Hangers for Mine Application

Ellis was approached by a customer who had a number of challenges around holding power and communications cables in a mine; the application was challenging due to the undulating nature of the wall and ceiling. The corrosive nature of the mine environment was also a challenge, so it was important that the correct material was supplied.

Bespoke Cable Hangers for Media Pavilion

The customer approached Ellis with a requirement for cable hangers. The cable hanger location and shape had been drawn on the overall sight plan. Ellis used this information to create a design that could be used with stock material and tooling, this was done to minimise lead time for the project.

UKPN London Power Tunnel

The London Power Tunnels project will create a new 32km electricity super highway deep below the capital, which will help keep Londoners connected to safe and reliable electricity supplies. In some areas of the system power is transmitted via 6 sets of cables in trefoil arrangement, to safely contain these cables a new trefoil cable cleat was required.

Do you need...

Expert help and advice

Case Studies

Siemens Helwin 2 Offshore Windfarm

Bespoke Cable Hangers for Train Tunnel Application

Bespoke Cable Hangers for Topside of Mine

Bespoke Cable Hangers for Mine Application

Bespoke Cable Hangers for Media Pavilion

UKPN London Power Tunnel