Powering the AI infrastructure boom

As investment in AI data centres accelerates worldwide, demand for fibre optic, power and connectivity cables is rising rapidly. Leibinger helps cable manufacturers turn this growth into reliable, efficient production output – with cable marking solutions developed for demanding extrusion processes.

Behind every AI model, cloud service and data centre is an extensive physical network. Fibre optic cables transmit vast volumes of data within data centres, between facilities and across long distance communication networks. Power and connectivity cables provide the energy and connections required to keep this infrastructure operating.

For cable manufacturers, the AI infrastructure boom creates growing order volumes, new applications and opportunities to expand production.

The central question is: how can manufacturers keep up with this rapidly growing demand with dependable output and on time delivery?

Many leading cable manufacturers around the world already rely on Leibinger coding solutions, including Prysmian, Corning and HFCL. Their applications range from industrial and building cables to high volume optical fibre cable production worldwide.

They all share the same objective: keeping their extrusion lines productive while ensuring that every cable leaves their factory with clear, durable and accurately positioned information.

The Leibinger Jet Rapid Wire is specifically designed for high speed cable, wire, pipe and tube production. It can mark extrusion products at speeds of up to 1000 metres per minute. Small characters down to 0.8 millimetres can be applied even to narrow cables. Specially developed printhead covers allow the cable to pass particularly close to the nozzle, supporting precise marking at maximum line speed – even on cables with diameters of five millimetres or less.

The contactless continuous inkjet (CIJ) process applies fixed and variable information directly onto the moving cable without affecting its surface.

Typical print content includes product and cable specifications, metre or feet markings, production dates and times, lot, batch and order numbers, standards and certification information, manufacturer and traceability data.

Flexible print job management, multiple fonts and languages, and industry specific software functions enable manufacturers to respond efficiently to changing products, markets and customer requirements.

Printer speed is only one part of reliable cable coding. The ink must also dry quickly, adhere securely and remain legible throughout winding, storage and further processing.

Leibinger develops and produces its own inks and matches them to the printer, cable material and production environment. The portfolio includes fast drying inks for high speed applications, formulations for hard to mark materials, as well as highly abrasion and transfer resistant inks.

Freshly printed cables are often wound onto reels immediately after marking. A suitable ink keeps the code exactly where it belongs instead of transferring a mirrored impression – often called a transfer or ghost print – onto the neighbouring cable layer.

For dark and black cables, the Jet Rapid Wire PI uses high contrast pigmented inks. Its integrated ink management system regularly stirs the ink inside the tank, maintaining a homogeneous pigment distribution and stable viscosity. This supports consistent, high contrast printing throughout production.

All Leibinger CIJ printers use automatic nozzle sealing technology. Whenever printing stops, the nozzle and ink circuit are sealed airtight while the ink remains in controlled circulation. This prevents the ink from drying inside the printhead. When the line restarts, the printer is immediately ready to continue – without routine printhead cleaning or lengthy start up procedures.

The result is more productivity per line and output gains from 20 to 50% when compared to traditional competitors.

‘While looking for a new CIJ equipment, we came across the company Leibinger. I have to say, this has been our best move so far. Previously, we had a cleaning effort of two to three hours a day, this is completely eliminated. I highly recommend the Leibinger company,’ said Jürgen Eberle, ABB Schweiz AG, Area PMA Kabelschutzsysteme, Switzerland.

Leibinger systems also offer straightforward integration, intuitive operation and flexible print job management. The Jet Rapid Wire provides numerous industrial interfaces for plug and print integration. For manufacturers with an additional focus on connectivity and resource efficiency, the IQJet offers OPC UA, an integrated PLC, and up to 50% lower solvent consumption than conventional CIJ printers. With dye based standard inks, it requires no scheduled maintenance for up to five years or 20,000 operating hours.

Cable production is one of Leibinger’s key industries. The company combines dedicated high speed and pigmented ink printers with in-house ink development, application testing and decades of extrusion expertise.

The appropriate solution is selected according to the cable material, colour, diameter, production speed, print content and downstream process. A global network of more than 150 partners provides local application knowledge and support close to cable manufacturers worldwide.

As AI infrastructure continues to expand, cable manufacturers need production systems capable of supporting the next phase of growth. Leibinger keeps extrusion lines moving, codes clear and production ready for rising global demand.