We produce special ropes with PVC coated steel core. However as you know PVC is vey hard so during roping strands are not strict enough around steel core. Is there a method for softening plastic coating or is there any material softer for coating.
I saw something like this done many years ago on already stranded wire rope with extruded and melt pumped polypropylene that was very close to or on its liquid phase temperature. This made total encapsulation possible and the process seemed fairly easy. I have no expertise in wire rope so I don't know if this makes any sense to you at all. It was just an observation in a wire rope plant.