AWG Line Diameter Variation Analysis in Ultra-Fine Coaxial Beam: High-Speed Signal Performance and Application Guide

Under the background of continuous acceleration in high speed, high frequency, and equipment miniaturization, micro-coaxial cable has become an important carrier for internal interconnection in modern electronic products. It is widely used in scenarios such as medical probes, drone data links, laptop hinges, camera modules, and射频 frontend. For these high-speed interconnection applications, the choice of AWG wire diameter has a decisive impact on signal loss, flexibility, impedance control, and durability.

In order to better guide engineering selection, this article will systematically analyze the performance differences and design trade-offs of different AWG in harnesses from the perspectives of electrical performance, structural characteristics, and application requirements.

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AWG Wire Diameter and Basic Physical Properties

The larger the AWG value, the finer the wire diameter. A thicker central conductor has lower DC resistance and higher mechanical strength, while a finer conductor can significantly improve flexibility, making it easier to route cables in tight spaces. The change in wire diameter not only affects transmission capacity but also affects processing consistency and the overall size of the cable assembly, which is a basic parameter that must be carefully considered in design.

 

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Two, Resistance and High-Frequency Loss

2.1 Direct Current Resistance

The conductor with a finer wire has a smaller cross-sectional area, so the direct current resistance is higher, and the voltage drop is more obvious; this impact is more prominent in power supply paths or low-frequency applications.

2.2 High-frequency attenuation

At GHz levels, the skin effect causes current to concentrate on the surface of the conductor, further reducing the effective transmission area of a thin wire diameter, significantly increasing high-frequency losses and attenuation; the dielectric loss of the insulating material will also amplify the transmission loss at high frequencies.

2.3 Transmission Distance
Thicker AWG can maintain lower losses over longer distances, while extremely thin AWG is more suitable for short-distance, high-density, and high-speed applications with low power.

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Z阻抗 control and signal integrity

The extremely thin coaxial cable束 usually has a 50Ω or 45Ω impedance. The diameter of the conductor, the thickness of the dielectric, and the shielding structure, among other minor geometric deviations, will affect the impedance consistency. The finer the AWG, the greater the proportion of geometric tolerances to the transmission structure, making the impedance more prone to deviation, which in turn can cause reflections, return loss, and degradation of eye diagrams. Therefore, when applied to high-speed, high-bandwidth links, fine AWG requires stricter manufacturing consistency and processing accuracy.

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Four, flexibility and mechanical durability

Extremely fine AWG (such as 40AWG and below) has high flexibility, suitable for frequent bending and narrow structure applications, such as camera module and laptop hinge. However, as the wire diameter becomes finer, the mechanical life is more easily affected, and the conductor is more prone to fatigue and breakage after long-term repeated bending. By contrast, lines with thicker AWG have higher mechanical strength and better durability, but flexibility decreases and are not suitable for high-density moving structures.


 

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AWG selection in different application scenarios

5.1 Ultra-short distance, high-density module interconnection

Within the camera module, AWG 40 or finer is usually selected to pursue extreme flexibility and lightweighting.

5.2 Medium-distance high-speed transmission

The cable harness for notebook displays can be optional from AWG 36 to 38, achieving a balance between signal bandwidth, loss control, and spatial constraints.

5.3 Long-distance or high-power paths

It is not recommended to use extremely thin AWG; instead, a thicker AWG or a larger specification coaxial cable should be chosen to improve transmission efficiency and reduce losses.

Each AWG wire diameter of the ultra-fine coaxial cable bundle has its respective advantages in high-speed interconnects. Thicker AWGs have lower loss, higher mechanical strength, and are more suitable for long-distance and high-power transmission; thinner AWGs are more suitable for short distances, compact spaces, and high-flexibility cabling, but have higher high-frequency loss and require higher precision in processing and impedance consistency. Engineers must combine frequency, distance, bending conditions, structural space, and overall reliability requirements when selecting types to make the most suitable cable scheme.

I amSuzhou Huichengyuan Electronic Technology Co., Ltd., Focused on the design and customization of high-speed signal cable harnesses and ultra-thin coaxial cable harnesses for a long time, committed to providing customers with stable and reliable high-speed interconnection solutions. For technical consultation or customization services, please contact:Manager Yin 18913280527(WeChat number)。