From Material to Technology: Unveiling the High-Performance Secrets of Extra-Fine Coaxial Cables

Under the background of continuously increasing demand for high-speed and high-frequency signal transmission, micro coaxial cable, with its miniaturized structure, high flexibility, and excellent signal performance, has been widely used in various fields such as consumer electronics, medical equipment, 5G communication, and aerospace. This article will analyze its core technologies and innovative directions from three aspects: structural design, signal control, and manufacturing process.

Part 1: Structural and Material Design
The extremely thin coaxial cable is composed of a micro central conductor (usually a multi-strand copper绞线 with 30～46 AWG) covered by an insulating layer, with a metallic braid or wrap shielding layer and a plastic sheath for protection on the outer layer. This structure provides excellent electromagnetic shielding performance while also considering the thinness, flexibility, and softness.
In higher requirement applications, to reduce dielectric loss and improve signal consistency, bubble PTFE and other low dielectric constant materials are often used as insulating media, enabling high-frequency signals to maintain stable transmission in complex environments.

Signal Integrity and Loss Control
The performance of ultra-fine coaxial cables lies in the strict control of signal loss. In engineering design, it is usually necessary to optimize insertion loss, return loss, and VSWR (Standing Wave Ratio) to ensure signal integrity and low reflection characteristics.
In addition, by using the "paddle card" structure (with PCB or FPC as the termination base plate), the circuit path can be shortened and impedance matching can be strengthened, thus significantly improving the high-frequency response and enhancing the overall transmission quality.

Section 3: Manufacturing and Connection Techniques
Due to the extremely thin diameter of micro coaxial cables, any minor error can affect performance. Traditional mechanical stripping methods have issues with precision fluctuations and tool wear, which are not suitable for high-density wire harnesses.
Therefore, laser stripping technology has become the mainstream choice. It adopts a non-contact processing method, using CO₂ or pulsed laser to achieve high-precision coating stripping and shielding layer window opening, which not only has high precision but also excellent repeatability and reliability, providing an ideal premise for subsequent terminal welding.

four application scenarios and innovative trends
Micro coaxial cable bundles have become an important carrier for high-density signal transmission in devices such as 5G, medical, industrial control, laptops, and smart terminals, especially playing a crucial role among modules such as motherboards, cameras, displays, and sensors.
With the continuous thinning and lightening of devices, as well as the improvement of resolution and refresh rate, the requirements for ultra-fine coaxial cables in terms of signal integrity, impedance matching, and bending performance are also increasingly stringent.
The future development trends mainly include:
High-density multi-core design: Meets the high-speed interconnection requirements of complex circuit modules.
Flexible and micro-bending optimization: Enhance wiring flexibility and reliability in confined spaces.
Material customization and insulation improvement: reduce transmission loss and enhance anti-interference performance.

The competitiveness of ultra-fine coaxial cables comes from the integration of material optimization, microstructure design, and high-precision technology. Their continuous breakthroughs in impedance control, shielding efficiency, welding technology, and flexible design make them an indispensable key component in modern high-frequency interconnect systems.
I amSuzhou Huichengyuan Electronics, Deeply rooted in the field of high-speed signal cable harnesses and ultra-thin coaxial cable harnesses, focusing on providing customers with customized solutions of high reliability and high-speed transmission. If you have relevant needs or want to learn more, please contact us:Manager Yin 18913280527 (WeChat number the same)。