Feller Power Cords
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R&D and In House Tool making

Feller´s in-house tool-and-die shop is equipped with state-of-the art machinery, including CNC spark-erosion machines. Several toolmakers are employed in a 2-shift operation.

Mold-tools, extrusion-dies, crimp-tools, and sub-assembly systems are customized and build in house. Some 70+ different mold-tools for national plug configurations, another 60+ mold-tools for connectors, plus close to 100 special and customized mold-tools are constantly maintained, updated, and being built for Feller´s 4 manufacturing plants.

Component-, product-, tool-, and system-design is carried out in the R&D department with a 3 D-CAD-system. CAD-data are routinely exchanged with customers and suppliers. 

Extrusion / Wire and Cable processing

Feller can process wires with various jacket insulation materials from single 22AWG to 5 conductor 4AWG.

In house Extrusion for PVC and PVC free cable is performed on 2 primary insulation extrusion lines with total of 4 extruders, 2 jacket extrusion lines (with a total of 3 extruders for Co-extrusion of various jacket-compounds), On 3 cabling machines an annual total of 55 million meters of multiple-core flexible cords with a cross-sectional range of 28 - 10 AWG (0,09 - 4,00 mm²) are being manufactured.

Cable cutting is done at all 4 manufacturing locations, as well as specialized cutting-, and crimping-, and sub-component-assembly-lines.


100% production line testing includes on-line diameter-control and spark-testing for bulk-cable, and ground-integrity, continuity of live and neutral wires, hi-pot wire-to-wire (3 kV), polarity, and hi-pot wire to-outer-contour (6 kV) for power supply cords.

All cords that have passed the above tests are automatically date-coded and/or needle marked. Defective cords are to be cut automatically.

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