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High-flex micro-coaxial cables are critical components in applications requiring repeated bending, such as robotics, medical devices, and wearable electronics. However, improper handling of bend radius limits can lead to premature cable failure, signal loss, or costly downtime. This article explores bend radius principles, calculation methods, and best practices to ensure reliable performance in high-flex designs.
The minimum bend radius (MBR) is the smallest radius a cable can safely bend without damaging its conductors, shielding, or dielectric layers. Exceeding this limit causes:
Most manufacturers specify MBR as a multiple of the cable’s outer diameter (OD). A common formula is:
MBR = 6–8 × OD (for dynamic bending)
MBR = 4–6 × OD (for static installations)**
Example: A micro-coaxial cable with a 1.2 mm OD would have:
Key factors influencing MBR:
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