Bowden Cables & Control Cable Assemblies
A Bowden cable is a flexible control cable that transmits mechanical force by having an internal wire that glides through an outer flexible casing. At Tyler Madison, every Bowden cable control system is custom engineered around this basic concept, with each assembly built from the same four core components.
There are 4 main components
- Conduit or casing
- Conduit fittings
- Inner wire or wire rope
- Wire rope end fittings
These four components form the core of every Bowden cable control system. If your application needs positive motion in both directions, a push pull control cable assembly is usually a better fit.
Need help selecting components? Talk to an engineer.
Our extensive knowledge and experience with Bowden cables enables us to produce both standard and specialized Bowden cable assemblies for a wide range of industrial clients.
Building Your Bowden Cable Control System
When you partner with Tyler Madison, we follow a proven three step process for Bowden cable control systems that mirrors how we construct our conduit assemblies. We match the inner cable, conduit, and hardware to your mechanical and environmental requirements so your Bowden cable assembly works as intended from day one..
1. Choose or Determine End Fittings
End fittings define how your inner wire connects to your handle, lever, latch, bracket, or actuator. They also help determine which inner wire diameter makes the most sense for your build. Most Bowden cable control systems use a few common inner wire sizes:
- 3/64 inch and 1/16 inch inner wire (widely used across many conduit styles)
- 3/32 inch inner wire (typically paired with larger conduit for higher loads)
- Larger than 3/32 inch is available for custom designs when the application requires it
What we confirm in this step:
- The connection style on both ends (ball, clevis, threaded stud, loop, stamped eye)
- Your pull load and expected cycle life
- Material needs (galvanized vs stainless, corrosion exposure, heat, washdown)
- Any packaging limits that affect fitting size or orientation
2. Choose Conduit Fittings
Once the inner wire and end fittings are defined, we match the conduit and conduit fittings that hold the system together. The conduit supports the inner wire, protects it through routing, and helps control friction and feel. Conduit fittings terminate the conduit and provide mounting, retention, and adjustment where needed.
Common Conduit Fittings
- End caps, ferrules, and retainers that secure the conduit at each end
- Threaded conduit fittings, bulkhead mounts, or snap-in styles for mounting through panels and brackets
- Adjusters or threaded hardware when you need fine tension and travel control
- Snap rings or threaded studs
Materials
- Material selection based on the environment (brass, galvanized steel, stainless steel)
- Threaded end terminals: made up of brass, galvanized steel, and stainless steel.
- Chromium plated or galvanized end caps
3. Confirm Lengths and Required Travel
The final step is confirming cable length and travel so the assembly installs cleanly and performs consistently in production. We will align on how you measure your Bowden cable, where the reference points are, and how much stroke (draw length) the system needs.
What we typically need from you
- Overall length and the exact measurement points you use
- Required stroke or draw length (how far the inner wire must move)
- Routing details (bend radius, clamp points, tight turns, moving interfaces)
- Return spring details, if applicable (force and location)
- Tolerance targets, build quantity, and whether this is prototype or production
Quick summary of the process:
End fittings → inner wire diameter → conduit size → conduit fittings → final lengths and draw length
How Our Assemblies Are Made
Control and Conduit assemblies are complete, pre-engineered systems that integrate flexible conduits with end connectors, and specific fittings on a sliding pre-installed inner wire, all tailored to meet the requirements of a particular application.
Constructing a Conduit Assembly
The process of creating a conduit assembly involves:
- Determine the Push pull length, or “play” of the inner wire and cut lengths: To the exact length required for the full assembly, taking into account the stretching of end fittings when crimping.
- Attaching Fittings: Using up to 120 ton swage machines to ensure secure end connections.
- Integrating Control Cables: Ensuring smooth operation of the inner wire and minimal friction within the conduit.
Design Tip:
- Design tip: The more we know about your pull load, routing, return spring, and how you measure cable length, the easier it is to engineer a Bowden cable that installs smoothly and operates the way you expect.
Need a Starting Point?
Send us your print, sample, or basic requirements and our engineering team will help you refine the right cable size, conduit, end fittings, and tolerances for your Bowden cable control system.
Important Design Considerations
Designing an effective conduit assembly requires careful attention to various factors to ensure optimal performance and longevity. Key considerations include:
- Push, Pull or Both: Push assemblies require a solid inner wire to transfer force, while pull assemblies have a flexible wire, allowing the full assembly to be fluidly installed into complex systems, but require a spring on the wire or connected to the wire to reset the wire actuation.
- Environmental Conditions: Assess the operating environment, including exposure to moisture, chemicals, extreme temperatures, or UV radiation. Selecting materials with the right resistance properties will enhance durability.
- Load and Motion Requirements: Consider the amount of force and type of motion the conduit will experience, such as bending, twisting, or stretching. Ensure the conduit’s flexibility matches the application’s needs.
- Cable Protection: Choose a conduit that provides adequate protection against abrasion, crushing, or external impact to safeguard the internal cable.
- Routing and Space Constraints: Plan the conduit’s path to avoid sharp bends or tight spaces that may compromise performance. Ensure proper routing to minimize friction and wear.
- Fittings and Connectors: Select fittings that ensure secure and reliable connections. The fittings should also provide proper sealing to prevent contaminants from entering the assembly.
- Material Selection: Use materials that balance strength, flexibility, and resistance to environmental factors. For instance, certain polymer coatings enhance flexibility or have chemical/UV resistance.
- Regulatory Compliance: Ensure the conduit assembly meets industry-specific standards and regulations for safety and performance.
- Installation and Maintenance: Design assemblies that are easy to install and maintain, reducing downtime and ensuring longevity.
Our Conduit Cable
Every Bowden cable assembly Tyler Madison builds uses our premium conduit, manufactured with tighter tolerances and fewer splices than industry standard alternatives. We stock lined, unlined, braided, and flat-wound conduit types across a range of sizes.
For full conduit specifications, types, liner and cover options, and bulk purchasing, see our Conduit product page.
Tyler Madison Inc.’s Bestsellers
Tyler Madison is a market leader in manufacturing custom cable of wire rope fittings, aircraft cables, Bowden cables, custom wire rope lanyards, and other steel cable assemblies.
Tyler Madison has the following range of conduits among our bestsellers:
Specifications
| Item | Diameter | Description | Lined | Cover | Fitment |
|---|---|---|---|---|---|
| 401-001 | .218 | Outer Diameter | HDPE | Vinyl | 1/16 diameter cable/wire and under |
| 401-002 | .325 | Outer Diameter | HDPE | HDPE | 3/32 diameter cable/wire and under |
| 444-002.5 | 7/32 | No liner |
What Sets Our Conduit Apart
At Tyler Madison, we take pride in offering premium Bowden conduit that outperforms standard alternatives on the market. The Bowden conduit we sell offers several key advantages over the standard options.
It all begins with the quality of your conduit…
Tyler Madison Conduit:
- Fewer Splices, Less Waste: Splices occur every 1000-2,000 feet, ensuring more usable length and less waste.
- Consistent Outer Coating: Features a uniform polymer thickness, providing exceptional durability and flexibility.
- Superior Quality, More Durable: Excellent for high performance applications
- Cost Effective: Through our partnerships, we’re able to provide superior conduit at a very competitive price, making it a smarter choice for bulk purchases and high-performance applications.
Industry Standard Conduit:
- More Splices, More Waste: Splices every 150-200 feet lead to 12x more waste and reduced efficiency.
- Inconsistent Coating: Inconsistent coating can result in cracks and reduced flexibility, compromising performance.
- More Expensive, Lower Quality: When it comes to control cable assemblies, the quality of the conduit used can make or break the functionality and durability of the finished product.
Visualize Your Next Bowden Cable Control System
See how Tyler Madison turns specs into real-world solutions. Cables engineered for your application. Ready to design yours? Request a custom Bowden cable assembly.
Key Features & Benefits
Key features, advantages and benefits of Tyler Madison’s Bowden cable control systems.
Flexible Conduit Routing
Custom-length routing with low friction for pull control around corners and through tight spaces.
Durable Materials
Galvanized or stainless steel inner cable and high quality conduit for strength and corrosion resistance.
Custom End Fittings
Choose from stops, sleeves, clevises, threaded studs, knobs, and other hardware to match your mechanism.
Smooth Pull Control
Lined conduit and matched components help reduce friction and provide consistent pull feel over the full stroke.
Low Maintenance
Quality wire rope, conduit, and fittings support long-term performance with minimal adjustment.
Where Are Conduit Assemblies Used?
Tyler Madison’s wire rope and steel cable assemblies have thousands of different applications and uses. We carry a large inventory of standard and stock rope assemblies, but excel in custom cable assemblies and cable end fittings. No matter what your application or industry, contact Tyler Madison first for a quick solution to your needs.
- Automotive Applications
- Medical Equipment
- Industry Machinery
- Aerospace Systems
- Marine Applications
- Consumer Products
- Robotics
- Agricultural Equipment
- Automotive Applications: Conduit assemblies are integral to automotive control systems, such as throttle cables, brake cables, gear shift mechanisms, and hood or trunk release systems. Their durability ensures reliable performance under constant movement and varying temperatures.
- Medical Equipment: In the medical field, conduit assemblies are used in devices like surgical equipment, patient beds, and diagnostic machines, where smooth and precise control is critical.
- Industrial Machinery: Heavy machinery in manufacturing plants relies on conduit assemblies to control mechanical movements, ensuring safety and efficiency in operations.
- Aerospace Systems: Conduit assemblies play a crucial role in aircraft control systems, providing precision in critical components such as flight control cables and landing gear systems. They are also used for less flight critical applications such reclining seats.
- Agricultural Equipment: From tractors to harvesters, conduit assemblies help control systems such as throttles, brakes, and other mechanical functions in agricultural machinery.
- Marine Applications: Used in boats and ships, conduit assemblies help manage throttle and steering cables, offering corrosion resistance and durability in marine environments.
- Consumer Products: Applications extend to fitness equipment, lawn and garden power tools, and home appliances that require motion control mechanisms.
- Robotics: Robotics and automation systems depend on conduit assemblies to protect and guide control cables for precise movements in various environments.
Bowden Cable Supplier & Manufacturer
Tyler Madison is a full-service manufacturer of custom control cable assemblies, including Bowden cable, push pull cables, wire rope assemblies, and related hardware. Our affordable products and advanced manufacturing capabilities make us a strong partner for your control cable needs.
We provide design and engineering support and can create functional prototypes before starting production. Whether you need a custom Bowden cable assembly, a complete Bowden cable control system, or cable conduit as a component, our team is ready to help.
Why Work With Tyler Madison for Bowden Cable
Tyler Madison is a dedicated control cable assembly manufacturer. Bowden cable is part of a larger offering that includes push pull cables, lanyards and wire rope assemblies.
As a US manufacturer, we ensure the required function and form for the end user by selecting the right components for the job. We also specialize in creating micro Bowden cables. Our customized Bowden cables, including micro variants, which are used in the robotic and medical industry.
Our goal is to deliver Bowden cable assemblies that fit your equipment, your environment, and your production schedule.
We Help OEMs:
- Select the right cable, conduit, and fittings for their loads and routing
- Prototype and test Bowden cable control systems before full production
- Consolidate sourcing for control cable assemblies and cable conduit
- Scale from small runs to high volume OEM programs with consistent quality
Bowden Cable FAQs
What is a Bowden cable control system?
A Bowden cable control system combines one or more Bowden cables with mounting hardware and actuators such as handles or levers so you can operate a device from a distance. For example, a hood release handle in the cabin pulls a Bowden cable that releases a latch in the engine bay. Tyler Madison designs and manufactures Bowden cable control systems as complete control cable assemblies.
What is a Bowden cable and how does it work?
A Bowden cable is a flexible control cable that uses an inner wire sliding inside a flexible outer conduit. When the inner wire is pulled or pushed, it transmits motion around bends so you can actuate levers, latches, or valves that are not in a straight line.
What is a conduit assembly?
A conduit assembly is a complete, pre-engineered system that integrates flexible conduits with end connectors, and specific fittings on a sliding pre-installed inner wire, all tailored to meet the requirements of a particular application. They’re used across a wide range of industries where precision, durability, and motion control are essential.
What is the difference between Bowden cable vs standard wire rope assembly?
A standard wire rope assembly is usually a bare cable with end fittings that works best in straight or gently curved paths. A Bowden cable includes both the inner wire and a fitted outer conduit, which guides the motion and allows the cable to snake through tight, complex routings while still delivering smooth actuation.
Are Bowden cable vs push pull cable the same thing?
Bowden cable is a general term for a flexible cable inside a conduit. Push pull cable assemblies are designed to both pull and push with controlled column strength in the center wire. Many push pull controls use Bowden-style conduit, but not all Bowden cables are engineered for push and pull loads. We can help you select the right construction for your stroke and load.
Is a Bowden cable the same as a control cable assembly?
A Bowden cable is one type of control cable assembly. It is usually a pull only design with an inner cable moving inside a flexible conduit. Other control cable assemblies, such as push pull cables, are designed to transmit force in both directions. If you are not sure which type you need, our team can review your application and recommend the right control cable assembly.
Do you make custom Bowden cable assemblies?
Yes. Custom Bowden cable assemblies are a core part of what we do. We can build simple prototypes, engineer new assemblies from your concept, or produce repeatable Bowden cable assemblies at production volumes. We size the cable, conduit, and fittings to your travel, load, routing, and environment.
What information do you need to design a custom Bowden cable assembly?
Helpful details include a sketch or CAD model of the routing, required stroke, desired actuation force, inner wire and conduit diameters, end fittings, mounting style, environment, and target life or cycle count. With that information, we can engineer a Bowden or push-pull assembly that feels right and meets your performance requirements.
How is Tyler Madison Bowden conduit different than competitors?
Many off-the-shelf control cables use conduit with frequent splices and inconsistent construction, which can create friction changes along the routing and reduce service life. Our Bowden conduit is manufactured with tighter tolerances and fewer splices, which helps deliver smoother feel, more consistent forces, and improved durability in demanding applications. Learn more about our conduit cable.
Can I purchase conduit separately, without ordering a complete assembly?
Yes. We supply premium Bowden conduit as a standalone product in cut-to-length quantities or custom orders with a minimum of 10,000 feet. Visit our Conduit product page for full specs and options, or contact us for pricing and samples.
How do Bowden cables compare to hydraulic or electronic actuation?
Bowden cables provide a simple, cost-effective way to transmit mechanical motion without fluids, power, or complex electronics. Hydraulic and electronic systems can handle higher loads and long distances but add cost, complexity, and maintenance. For many mechanical controls, a well-designed Bowden cable is the most economical and reliable solution.
Where are Bowden cables commonly used?
Bowden cable is used anywhere you need remote pull control and the device returns on its own. Typical applications include:
- Parking brake release cables
- Hood and trunk release cables
- Throttle and choke controls on engines and power equipment
- Seat adjusters and latch releases
- HVAC dampers and vents
- Light duty mechanical controls in industrial and specialty equipment
If your mechanism has a return spring and you only need pull force, a Bowden cable is often the most straightforward control solution