ACCC Conductor consists of a hybrid carbon and glass fiber core which is wrapped with trapezoidal shaped aluminum strands. The high strength structural core carries most of the conductor’s mechanical load, while the fully annealed aluminum strands carry all of the conductor’s electrical current. The patented composite core is manufactured using a proprietary pultrusion process, wherein carbon and glass fibers are impregnated with a "toughened" high-temperature epoxy resin, and pulled through a heated pultrusion die which quickly cures the resin. The resin serves to bond the individual fibers together which helps transfer and share the tensile and shear loads between them. The carbon fibers provide an exceptionally high level of tensile strength and low coefficient of thermal expansion, while the glass fibers improve the core’s flexural strength, provide impact resistance, and prevent a galvanic response between the carbon fibers and the aluminum strands.

ACCC Conductor’s composite core is much lighter and stronger than a conventional or high-strength steel core. Its lighter weight allows the incorporation of 25% to 30% more aluminum (conductive material) without any weight penalty. Using compact trapezoidal shaped aluminum strands avoids any diameter penalty. Together, the conductor provides higher line capacity and lower line losses and, coupled with the ACCC Conductor’s greater strength, fewer structures are required for new lines.