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1 mm of PTFE on a 10 kV cable is not even remotely close to human safe. Nick the insulation on such a cable and you turn your user into a quickly expanding cloud of plasma. Cables for that sorts of voltages and currents come heavily armored for mechanical stability, not only dielectric strength.


A 100um thick layer of foil mid-way through the PTFE, together with capacitance testing between the conductor and the foil will allow software to detect any knicks before they get deep enough to do damage. Adds <5 grams to the weight. Also, any high voltage system would use a balanced +- non-ground-bonded (ie. floating) supply, so a human could touch one or other bare copper conductor without risk anyway.

Far more user and environmentally friendly than todays engineering approach of "just make the insulation really thick and weigh a ton while the electronics are dumb and wouldn't even notice if you hammered a nail through the conductor".


Feel free to develop a system that can provide high voltage cabling at a fraction of the cost of traditional methods if you think it's so easy. You'll have a boatload of money waiting for you.

Also, there's already plenty of electronics in most cabling setups for EVs that definitely WOULD notice if you ran a nail through the conductors. What you're proposing just isn't safe.


Others have commented on technical feasibility already, but I want to point out, this is not sitting in an office powering a smoothie machine. It will be in contact with dust, dirt, debris and tools, and angry people. Your 1 mm of insulation will not last a week.




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