How to repair a torn Apple charging cable (Mac, iPhone, iPad, etc.)?

Apple users are aware of the issue with original cables. Over time, they tear near the connector, and new original cables are quite expensive. The price issue was quite critical before the introduction of the universal Type-C. Currently, Type-C is a common standard and can be purchased at a low price. In this post, we will discuss the reasons for Apple cable problems, a repair option using heat shrink tubing, and a life hack from Reddit that may extend its lifespan.

Personally, I dislike this story, but it is related to the right and wrong decisions made by the company. For example, Apple designers removed the strain relief part from the cables (the thing that relieves tension when bending the wire) considering it visually unappealing. Engineers, knowing the consequences, accepted this decision. As a result, we have a lot of negative experiences, and possibly sales of new wires. It should also be noted that Apple is trying to be as “green” as possible and reduce the use of non-ecological materials. So they abandoned PVC (polyvinyl chloride, plastic) and use rubber for cables, the composition of which is not disclosed, but which is supposed to decompose quickly. This material is less durable than plastic. That is: the absence of a strain relief element at the bend of the cable + weak rubber as insulation = the problem of torn cables near the connector.

I have had several iPhones and MacBooks, and each time I had a problem with the cable. I tried to fix it with duct tape, but that option doesn't work. Firstly, the duct tape starts to unravel over time, and the wire begins to break in a new place (immediately after the duct tape). If you remove the duct tape, you will see that the rubber from the cable along with the glue from the duct tape has turned into mush, exposing the cable. And it looks quite unesthetic (I think more unesthetic than a cable with a strain relief element).

I googled information about possible solutions to this problem and even found businesses built around this issue. Specifically, a ‘special glue’ that was essentially ordinary liquid insulation packaged in small bottles, but with the label ‘For Apple Products’ and a price x10. A few times I used a silicone gun. I also used a life hack from Reddit - I put a spring from a pen as a strain relief element. But over time, the insulation of the cable simply started to tear everywhere the spring pressed and a bit further.

So all these repair options are temporary. But there is good news (maybe). Apple has started using a new type of cable insulation, namely - woven. It is supposed to hold better, but it also has its drawbacks. For example, woven insulation is harder to clean from dirt. Currently, I have such a wire (it came with the new MacBook), but I do not use it. I am finishing off the Type-C cable with rubber insulation. Today we will consider the option of fixing this cable using heat shrink tubing (this is also a temporary solution and most likely the wire will start tearing further, so over time I will update this post).

Heat shrink tubing is a tube made of insulating material that shrinks under the influence of heat. That is, you need to stretch this tube over the area that needs to be insulated and heat it.

Usually, electricians use a heat gun for this. And at home, you can carefully use a lighter. I tried a regular hair dryer at 2600W. The tube shrank, but not enough - I finished it off with a lighter. Not great... But it works. We find a tube of the right size (so that the connector fits) and heat it.

We heat it so that the tube fits snugly.

We get an insulated cable. If there are black marks left from the lighter - just wipe them off (for example, with a damp cloth).

Most likely the insulation will deteriorate after the tubing. We will see. I will update this post. I hope the woven cables will behave better.