How difficult is it to process ultra-fine coaxial cables? From the perspective of technology, it shows real skills.

In today's rapidly developing field of high-speed signal transmission, extremely thin coaxial cables (Micro Coaxial Cable) have become an indispensable core component in precision electronic equipment. Whether it is the camera module of a smartphone, the LCD connection line of a laptop, or the endoscope in medical equipment and camera modules of drones, they all rely on its support. Compared with ordinary cables, the manufacturing and processing process of extremely thin coaxial cables is much more complex, and each link puts extremely high requirements on precision and technological level.

The structure is precise, with extremely strict requirements for size control.
The outer diameter of extremely thin coaxial cables is usually only 0.3mm to 0.5mm, even thinner. Such a small size means that each layer structure——conductor, insulation, shielding layer, and sheath——must maintain extremely high precision. Any slight dimensional deviation may cause impedance change, leading to signal distortion. Therefore, in the manufacturing process, strict control over peeling and cutting precision is necessary, and specialized miniature processing equipment and high-precision fixtures are also required to ensure that every cable bundle meets the design standards.

Two, strict design requirements for shielding
Due to the extremely small diameter of ultra-fine coaxial cables, their shielding layer thickness is limited, but they must also have strong anti-interference performance. For this purpose, manufacturers usually adopt a high-density woven structure, or combine metal foil with woven layers to form multi-layer composite shielding. This design can effectively suppress electromagnetic interference (EMI) and ensure the integrity of the signal during high-speed transmission. However, any uneven weaving, poor overlap, or loose issues will directly affect the shielding effect and product consistency.

Three, technical challenges of welding and assembly
The welding technology for extremely thin coaxial cables can be described as "true skill is seen in the smallest details." The weld points are extremely minute, overheating can easily burn the insulation layer, and welding deviation may cause false welding or short circuit. Therefore, it is usually necessary to complete the manual welding under a microscope or adopt automated spot welding equipment to achieve high-precision control. At the same time, parameters such as the stripping length of the coaxial cable and the welding position of the terminals all need to be strictly controlled; otherwise, it will seriously affect the yield and product performance.

Four, promote process improvement in application fields
The application range of extremely thin coaxial cables is extremely wide, particularly focusing on high-end fields where both signal integrity and lightweighting are required: in the consumer electronics field for mobile phones, tablets, and notebook LCD modules; in the medical equipment field such as endoscopes and ultrasonic probes; in industrial detection with high-speed cameras and machine vision systems; and in lightweight signal transmission systems for drones and aerospace. Different application scenarios have extremely high requirements for flexibility, bend resistance, and reliability, so the level of craftsmanship directly determines the competitiveness of the product.

Extremely thin coaxial cables are small but they are a key component supporting high-speed transmission in electronic devices. They not only reflect the limit of microfabrication technology but also represent an important embodiment of high-end interconnect technology. Only enterprises with high-precision and high-consistency processing capabilities can occupy a leading position in the future high-speed interconnect industry.
I amSuzhou Huichengyuan Electronics, Focus on the design and customization of high-speed cable harnesses and ultra-fine coaxial cable harnesses for a long time, 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)。