BSTFLEX Sewn Wire Supported Bellows are custom flexible protective covers designed for large-diameter, long-stroke and demanding industrial applications. An internal wire support structure helps maintain the bellows shape during extension and compression, reducing fabric sagging and improving stability during repeated machine movement.
These wire reinforced fabric bellows are suitable for protecting hydraulic cylinders, shafts, actuators, telescoping mechanisms and other moving components from dust, metal chips, abrasion, oil, coolant, sparks and heat.
Each bellows can be customized in inside diameter, outside diameter, compressed length, extended length, stroke, wire spacing, fabric material and mounting configuration. Coated nylon, silicone coated fiberglass, PTFE coated fiberglass, aluminized fiberglass and other technical fabrics are available for standard or high-temperature applications.
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1BSTFLEX Sewn Wire Supported Bellows are custom flexible protective covers designed for large-diameter, long-stroke and demanding industrial applications where conventional unsupported fabric bellows may not maintain sufficient shape or stability.
The bellows are constructed from flexible industrial fabric combined with an internal wire support system. The wire reinforcement helps maintain the circular profile of the bellows during extension and compression, reduces fabric sagging, and provides controlled movement over long travel distances.
This construction is particularly suitable for large shafts, hydraulic cylinders, actuators, telescoping assemblies and industrial machinery exposed to dust, metal particles, oil, coolant, abrasion, heat and other contaminants.
The defining feature of this bellows design is the internal wire framework.
Instead of relying entirely on the stiffness of the fabric folds, the supporting wire helps form and stabilize each convolution. This allows large-diameter bellows to remain more consistent in shape during repeated machine movement.
The construction offers several advantages:
CQM similarly describes wire supported bellows as particularly efficient for large-diameter round designs and long bellows because of the reinforced wire skeleton.
BSTFLEX manufactures wire supported bellows according to the actual dimensions, stroke and available installation space of the equipment.
| Specification | Custom Options |
|---|---|
| Bellows Type | Wire Supported Sewn Bellows |
| Shape | Round / Cylindrical |
| Inside Diameter | Custom |
| Outside Diameter | Custom |
| Extended Length | Custom |
| Compressed Length | Custom |
| Stroke | According to application |
| Wire Support | Custom diameter and spacing |
| Fabric Material | According to environment |
| End Construction | Collar, flange, clamp or custom |
| Closure | Closed, zipper, hook-and-loop or custom |
| Production | Prototype and OEM quantities |
Wire diameter, support spacing and convolution geometry can be adjusted according to bellows diameter, movement frequency and required structural stability.
Large-diameter protective bellows present different engineering challenges from smaller conventional sewn bellows.
As diameter increases, unsupported fabric can become more susceptible to:
The wire-supported construction helps maintain the bellows profile throughout movement and is therefore particularly suitable for large industrial equipment.
Typical applications include:
Wire supported bellows are also effective where a large difference exists between fully compressed and fully extended length.
The internal support structure allows multiple controlled folds to expand over long travel distances while maintaining a relatively compact compressed configuration.
This makes the design suitable for:
BSTFLEX can manufacture wire supported fabric bellows using different technical textiles depending on temperature, abrasion, oil, chemicals and environmental exposure.
Suitable for general industrial machine protection requiring flexibility, abrasion resistance and contamination protection.
Recommended for elevated-temperature applications and machinery exposed to heat, sparks or hot surfaces.
Suitable for environments requiring temperature resistance, chemical resistance and reduced surface adhesion.
Used where radiant heat reflection is required around furnaces, foundries, hot machinery or processing equipment.
Special constructions can be developed for applications exposed to severe heat, hot particles and demanding industrial environments.
CQM also lists coated nylon, PTFE-coated fiberglass, silicone-coated fiberglass and aluminized fabrics within its sewn bellows material range.
Wire supported construction is particularly useful for high-temperature bellows because many heat-resistant technical fabrics are less suitable for forming rigid self-supporting accordion structures.
The internal wire system helps maintain bellows geometry while allowing heat-resistant fabrics to remain flexible.
Depending on the application, BSTFLEX can evaluate materials for exposure to:
The fabric, sewing thread, support wire and mounting hardware should all be selected according to actual operating conditions.
Sewn wire supported bellows can protect moving components from:
Typical protected components include:
CQM also positions sewn bellows for protection of ball screws, lead screws, shafts, cylinder rods, linear rails and machine ways in machine-tool applications.
BSTFLEX can incorporate different end configurations according to machine design.
Available options include:
For equipment that cannot easily be dismantled, split or zippered wire-supported constructions can also be evaluated.
BSTFLEX Sewn Wire Supported Bellows are suitable for:
For quotation and design evaluation, please provide:
BSTFLEX can evaluate the required fabric, wire support spacing, fold geometry and mounting configuration according to the actual application.
BSTFLEX combines custom industrial sewing capability with experience in high-temperature technical fabrics. This allows us to develop wire supported bellows not only for conventional machine protection, but also for large-diameter and high-temperature applications where standard fabric bellows may not provide sufficient structural stability.
Custom dimensions, wire reinforcement, special materials, mounting arrangements and OEM production are available.
Send us your dimensions, required stroke, operating temperature and application drawing for evaluation.
If you have questions or suggestions, please leave us a message,we will reply you as soon as we can!
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