Don't be deceived by appearances: ultra-thin coaxial cables are actually very sturdy.

Many people have such doubts when they first receive micro coax (micro coaxial cable) - "This wire is so thin, won't it break if I pull it?" In fact, such concerns are completely unnecessary. Although the micro coaxial cable looks slender, its internal structure is as solid as that of traditional coaxial cables. It is precisely because of its excellent mechanical and electrical performance that it is widely used in high reliability fields such as medical probes, camera modules, drones, and industrial testing equipment.

Structure is precise, strength comes from overall design
The structure of ultra-fine coaxial cables is clearly layered, including conductor, insulation layer, shielding layer, and outer sheath, each layer having its unique function. The conductor is usually made of copper or copper alloy, and sometimes it is subjected to special reinforcement treatment to enhance its tensile strength. The insulation layer is often made of high polymer materials such as PTFE or FEP, which can maintain excellent electrical properties while also having good flexibility. The shielding layer is woven from fine copper wires, which can effectively prevent electromagnetic interference and also distribute mechanical tension. The outer sheath may sometimes be reinforced with wear-resistant materials to maintain stability even in applications involving frequent bending. Therefore, the reliability of ultra-fine coaxial cables does not rely on a single material but rather on the combined action of multi-layer structures.

Excellent mechanical properties
Although extremely thin coaxial cables are finer than traditional cables, their mechanical properties are far from fragile. Firstly, the tensile strength is sufficient to withstand the pull forces required for daily operations within a reasonable design range; many models can achieve several newtons of tensile force in terminal separation tests. Secondly, the bending life is concerned, with the general recommendation for the minimum bending radius being six times the wire diameter, but products with improved designs can withstand thousands of repeated tests even with a bending radius of 1 millimeter. Thirdly, the torsional life test, which is commonly a standard of ±180° or ±360° of repeated rotation cycles, can still maintain stable electrical properties under long-term stress. It is for this reason that extremely thin coaxial cables can be widely used in high-precision and high-frequency equipment.

III. Common Questions and Solutions
In practical applications, micro coaxial cables may also encounter some mechanical failure issues. For example, conductor breakage is often caused by stress concentration, which can be improved by adding stress relief structures. Breakage of the shielding layer usually occurs at locations with frequent bending, which can be addressed by using a higher density braiding method or thickening the outer sheath. Insulation delamination problems are often related to insufficient adhesion of materials, which can be effectively avoided by optimizing raw materials and processing technology. Although these issues may seem complex, they can all be resolved through preventive measures in the design and manufacturing stages.

Four, reliability originates from system design
Extremely thin coaxial cables, although with small size and complex structure, have completely sufficient mechanical strength, flexibility, and durability to meet the high standards of medical, communication, and imaging fields. Designers need to consider the stress conditions of stretching, bending, and twisting early in the project, rather than simply focusing on electrical performance. Only when the structural design, material selection, and process control are coordinated and unified, can micro coax truly demonstrate its "slender yet strong" characteristics and become a key connection solution in high-end electronic equipment.

The ultra-fine coaxial cable is not a fragile and easily broken cable, but a high-performance and high-reliability precision interconnect component. Its strength comes from the collaborative action of multi-layer materials and rigorous manufacturing processes. As long as it is used and designed correctly, the micro coax can excel in terms of reliability and durability.
I am[Suzhou Huichengyuan Electronics],Long-term focus on the design and customization of high-speed signal cable harnesses and ultra-thin coaxial cable harnesses, committed to providing stable and reliable high-speed interconnect solutions. If you have related needs or want to learn more, please contact:Manager Yin 18913280527 (WeChat same number)。