Coaxial Cable Technical Documentation Made Public - Micro Coaxial Cable factory-(FRS)

In the rapidly evolving fields of telecommunications, broadcast engineering, and data transmission, coaxial cables remain a critical backbone for reliable signal delivery. Recognizing the industry’s need for transparency in manufacturing standards and technical specifications, we are now making our comprehensive coaxial cable technical documentation publicly available. This initiative aims to empower engineers, procurement teams, and industry partners with clear, actionable insights into coaxial cable manufacture—from raw material selection to final quality validation. By demystifying the manufacturing process, we hope to set a benchmark for consistency, drive innovation, and help stakeholders make informed decisions when sourcing or integrating coaxial cables.

1. Core Specifications for Coaxial Cable Manufacture

A high-performance coaxial cable starts with strict adherence to technical specifications, which directly impact signal integrity, durability, and compatibility. Our public documentation outlines non-negotiable parameters for each component, ensuring alignment with global standards (e.g., ISO 11801, ANSI/TIA-568-C.4) and industry-specific requirements (e.g., for 5G base stations, satellite communications, or industrial control systems).

1.1 Conductor Material & Design

The conductor is the foundation of signal transmission, and its manufacture demands precision:

• Material Selection: We specify high-purity copper (99.99% minimum purity) or tinned copper for most applications. Copper ensures low electrical resistance, minimizing signal loss (attenuation) over distance. For lightweight or cost-sensitive use cases (e.g., automotive wiring), we include guidelines for aluminum-clad copper (ACC) conductors, with strict limits on aluminum thickness to avoid performance degradation.
• Stranding & Gauge: The documentation details conductor stranding options—from solid conductors (ideal for fixed installations with minimal bending) to stranded conductors (flexible for dynamic environments like robotics). Gauge sizes range from 14 AWG (for high-power applications) to 26 AWG (for compact, low-signal setups), with cross-sectional area tolerances of ±5% to ensure consistent electrical performance.

1.2 Insulation Layer Manufacturing

The insulation layer separates the conductor from the outer shield, preventing signal leakage (crosstalk) and protecting against environmental interference. Key manufacturing criteria include:

• Material: We prioritize fluoropolymer-based insulators (e.g., PTFE, FEP) for their high temperature resistance (-60°C to 200°C) and low dielectric constant (εr = 2.1–2.3), which reduces signal dispersion. For lower-cost, general-purpose cables, polyethylene (PE) or polypropylene (PP) insulators are approved, with mandatory tests for dielectric strength (minimum 10 kV/mm) and moisture resistance.
• Extrusion Process: The documentation specifies extrusion parameters such as temperature profiles (PE: 160–200°C; PTFE: 380–420°C), line speed (10–30 m/min), and wall thickness uniformity (tolerance ±0.02 mm). These controls ensure the insulation layer adheres tightly to the conductor without gaps, which could cause signal reflections.

1.3 Shielding Configuration

Shielding is critical for blocking electromagnetic interference (EMI) and radio frequency interference (RFI)—common challenges in industrial or urban environments. Our manufacture guidelines cover:

• Single vs. Double Shielding: For standard applications (e.g., home internet), a single braided shield (90% minimum coverage) is sufficient. For high-interference settings (e.g., near power lines or MRI machines), double shielding (braided + foil) is required, with foil overlap of ≥25% to eliminate gaps.
• Shield Material: Tinned copper or aluminum is used for braided shields, with wire diameter specified (0.10–0.15 mm) to balance flexibility and shielding effectiveness. Foil shields are typically aluminum-polyester laminates, with a minimum thickness of 0.02 mm.

1.4 Outer Jacket Production

The outer jacket protects the cable from physical damage, chemicals, and weathering. Manufacture requirements include:

• Material: PVC (for indoor use, with flame retardancy per UL 94 V-0) or polyurethane (PU) (for outdoor/industrial use, with UV resistance and oil resistance). For harsh environments (e.g., marine or mining), chlorosulfonated polyethylene (CSPE) jackets are recommended, with tests for abrasion resistance (≥500 cycles per ASTM D4703).
• Jacket Thickness: Depending on the application, jacket thickness ranges from 0.5 mm (indoor patch cables) to 2.0 mm (outdoor direct-burial cables), with a minimum tensile strength of 12 MPa to prevent tearing during installation.

2. Step-by-Step Coaxial Cable Manufacturing Process

Transparency in workflow is key to replicable quality. Our documentation breaks down coaxial cable manufacture into 6 sequential stages, each with defined checkpoints to prevent defects.

2.1 Raw Material Inspection (Stage 1)

Before production begins, all materials undergo rigorous testing to eliminate substandard inputs:

• Conductors are tested for electrical resistance (per ASTM B193) and tensile strength (minimum 220 MPa for copper).
• Insulation materials are checked for dielectric constant (using a capacitance bridge) and thermal stability (via thermogravimetric analysis, TGA).
• Shielding wires and jackets are verified for material composition (via FTIR spectroscopy) and dimensional accuracy (using a laser micrometer).

2.2 Conductor Preparation (Stage 2)

For stranded conductors, individual wire strands are twisted together using a stranding machine at a controlled pitch (10–20 times the conductor diameter) to ensure flexibility without signal loss. Solid conductors are drawn from copper rods through a series of dies to achieve the desired gauge, with annealing (heating to 400–500°C) to reduce brittleness.

2.3 Insulation Extrusion (Stage 3)

The prepared conductor is fed into an extrusion line, where the insulation material is melted and applied in a single pass. A crosshead die ensures uniform wall thickness, and a cooling tank (water or air) rapidly solidifies the insulation to maintain dimensional stability. Post-extrusion, the insulated conductor (called a “core”) is checked for eccentricity (maximum 5% deviation from center) to avoid impedance mismatches.

2.4 Shielding Application (Stage 4)

Shielding is applied in one of two ways, depending on the design:

• Braiding: A braiding machine weaves shield wires around the insulation core at a density of 60–90 picks per inch (PPI), ensuring consistent coverage.
• Foil Wrapping: A foil applicator wraps the core with aluminum-polyester foil, using a slight overlap to create a continuous barrier. For double shielding, braiding is applied over the foil.

2.5 Jacket Extrusion (Stage 5)

The shielded core is fed into a second extrusion line, where the outer jacket is applied. Similar to insulation extrusion, temperature and line speed are calibrated to the jacket material (e.g., higher temperatures for PU than PVC). After extrusion, the cable is cooled and cut to standard lengths (100m, 200m, or custom lengths) using a precision cutter.

2.6 Final Testing & Quality Control (Stage 6)

Every batch of coaxial cable undergoes 10+ tests to ensure compliance with specifications:

• Electrical Tests: Attenuation (measured at 100 MHz, 1 GHz, and 10 GHz), characteristic impedance (50Ω or 75Ω, tolerance ±2Ω), and return loss (minimum -20 dB at 1 GHz).
• Mechanical Tests: Flex life (≥10,000 cycles for stranded conductors), crush resistance (minimum 1000 N/m for 10 seconds), and impact resistance (no damage after 1kg weight drop from 1m).
• Environmental Tests: Temperature cycling (-40°C to 85°C for 100 cycles), humidity resistance (95% RH at 60°C for 1000 hours), and UV exposure (1000 hours per ASTM G154).

3. Addressing Common Challenges in Coaxial Cable Manufacture

Even with strict processes, manufacturers face recurring issues that impact quality. Our technical documentation includes troubleshooting guides for 3 critical pain points:

3.1 Impedance Mismatch

Impedance mismatch (deviation from 50Ω/75Ω) causes signal reflections, reducing transmission efficiency. The documentation identifies root causes in manufacture:

• Uneven insulation wall thickness (fixed by calibrating the extrusion die).
• Variations in conductor diameter (resolved by tighter control of the drawing process).
• Shielding gaps (fixed by increasing braid PPI or foil overlap).

3.2 Signal Attenuation

High attenuation (signal loss) often stems from suboptimal material or process choices:

• Using low-purity copper (solved by sourcing 99.99% pure copper).
• Overheating insulation during extrusion (fixed by adjusting temperature profiles).
• Poor shield contact (resolved by ensuring the shield is tightly bonded to the insulation).

3.3 Environmental Degradation

Outdoor cables may fail due to moisture ingress or UV damage:

• Jacket cracks (solved by using UV-stabilized PU or CSPE).
• Water penetration (fixed by adding a water-blocking tape between the shield and jacket).

4. Why FRS Factory Is Your Trusted Partner for Coaxial Cable Manufacture

The technical standards outlined in this public documentation are not just guidelines—they are the foundation of FRS Factory’s manufacturing operations. For over 15 years, we have specialized in producing high-performance coaxial cables that meet or exceed the specifications detailed here, making us a preferred partner for industries ranging from telecommunications to aerospace.

At FRS, we integrate every step of the coaxial cable manufacture process into a closed-loop quality system:

• We source raw materials exclusively from certified suppliers, with in-house testing to verify conductor purity, insulation dielectric properties, and shield effectiveness.
• Our production lines feature automated extrusion and braiding machines, calibrated to the exact temperature and speed parameters in the technical documentation, ensuring consistent wall thickness and shielding coverage.
• Every cable undergoes 100% electrical and mechanical testing before shipment, with test reports provided to customers for full traceability.

Beyond compliance, FRS offers customization to meet unique application needs—whether you require a ultra-flexible cable for robotics, a flame-retardant cable for data centers, or a ruggedized cable for outdoor 5G deployments. Our engineering team works closely with customers to adapt the manufacturing process to specific requirements, without compromising on performance or reliability.

When you choose FRS, you are not just buying a coaxial cable—you are partnering with a manufacturer that prioritizes transparency, quality, and innovation. Our public technical documentation is a testament to this commitment, and we stand ready to deliver cables that power your critical systems, today and tomorrow.