How to Select the Right Cable for High-Frequency Devices

Choosing the optimal cable for high-frequency devices is critical to ensuring signal integrity, minimizing losses, and achieving reliable performance in applications ranging from 5G base stations to radar systems and medical imaging. With frequencies often exceeding 10 GHz, even minor design oversights can lead to phase errors, impedance mismatches, or electromagnetic interference (EMI).

1. ‌Key Performance Parameters‌
   ‌A. Frequency Range‌
   The cable must support the operating frequency of the device.

‌Sub-6 GHz‌: Flexible cables (e.g., RG-58, LMR-195) are sufficient for Wi-Fi, LTE, and 5G FR1.
‌mmWave (24–110 GHz)‌: Semi-rigid or micro-coaxial cables (e.g., 1.0mm OD with PTFE dielectric) are mandatory for 5G FR2, satellite links, and automotive radar.
‌B. Insertion Loss‌
Loss increases with frequency and cable length. Use the formula:

Loss (dB)

×

×

Loss (dB)=α×
f
​
×L
Where

α = attenuation coefficient,

f = frequency (GHz),

L = length (m).

Cable Type Attenuation (dB/m @ 10 GHz) Max Frequency (GHz)
RG-58 (PE dielectric) 0.8 3
LMR-400 (foam PE) 0.2 6
Semi-rigid (PTFE) 0.1 110
‌C. Phase Stability‌
Critical for phased arrays and beamforming systems.

‌Requirement‌: <0.5° variation per meter at 28 GHz.
‌Solution‌: Semi-rigid cables with solid copper shields minimize phase drift under temperature shifts.
‌D. Shielding Effectiveness (SE)‌
Prevents EMI/RFI in dense electronic environments.

‌Low-Noise Labs‌: >120 dB SE (double-shielded cables).
‌Industrial Settings‌: >90 dB SE (braided copper + foil).

2. ‌Material Considerations‌
   ‌A. Conductors‌
   ‌Inner Conductor‌:
   ‌Copper-Clad Steel (CCS)‌: Balances strength and conductivity (e.g., 50% IACS).
   ‌Silver-Plated Copper‌: Reduces skin effect losses above 10 GHz.
   ‌Outer Conductor‌:
   ‌Semi-Rigid‌: Solid copper/aluminum for EMI shielding.
   ‌Flexible‌: Braided copper + aluminum foil (e.g., Times Microwave LMR series).
   ‌B. Dielectric Materials‌
   Material Dielectric Constant (εᵣ) Loss Tangent (tan δ) Applications
   ‌PTFE‌ 2.1 0.0003 Aerospace, mmWave
   ‌Foam Polyethylene‌ 1.5 0.001 Cellular base stations
   ‌Liquid Crystal Polymer (LCP)‌ 2.9 0.002 Foldable phones, IoT
   ‌C. Jacketing‌
   ‌Outdoor Use‌: UV-resistant polyethylene (PE) or fluoropolymers (e.g., PVDF).
   ‌Medical‌: Silicone jackets (ISO 10993 biocompatibility).
3. ‌Application-Specific Requirements‌
   ‌A. 5G/6G Infrastructure‌
   ‌Massive MIMO Antennas‌: Phase-matched semi-rigid cables (e.g., HUBER+SUHNER Sucoflex 104) for 64T64R configurations.
   ‌mmWave Small Cells‌: Ultra-low loss 1.13mm cables (Rosenberger MXH series) with bend radius ≤5× OD.
   ‌B. Automotive Radar (77 GHz)‌
   ‌Key Metrics‌:
   VSWR <1.25:1 over -40°C to +125°C.
   200% elongation tolerance for vibration resistance.
   ‌Example‌: Yazaki 0.5mm coaxial cables with LCP dielectric.
   ‌C. Medical Imaging (MRI)‌
   ‌Non-Magnetic‌: CuNi9Sn2 conductors (magnetic susceptibility <0.01 ppm).
   ‌High Flexibility‌: 100,000+ bend cycles for patient coil systems.
   ‌D. Aerospace & Defense‌
   ‌MIL-STD Compliance‌: MIL-DTL-17 for shock/vibration resistance.
   ‌Outgassing‌: TML <1% (NASA ASTM E595).
4. ‌Mechanical and Environmental Factors‌
   ‌A. Bend Radius and Flexibility‌
   ‌Static Installations‌: 10× OD bend radius (e.g., RG-8X).
   ‌Dynamic Applications‌: 5× OD with helical shielding (e.g., Molex FlexiCore).
   ‌B. Temperature Range‌
   Environment Temperature Range Cable Type
   ‌Satellite (LEO)‌ -65°C to +150°C PTFE semi-rigid
   ‌Automotive Engine‌ -40°C to +175°C Silicone-jacketed LMR-200
   ‌C. Chemical Resistance‌
   ‌Industrial Robots‌: Oil-resistant PUR jackets (ISO 6722).
   ‌Marine Systems‌: Saltwater-proof FEP jackets.
5. ‌Standards and Certifications‌
   Standard Scope Relevance
   ‌MIL-STD-202‌ Vibration/thermal cycling Defense and aerospace
   ‌IEC 61196-1‌ RF cable performance Telecom and consumer
   ‌3GPP TS 38.104‌ 5G NR base station requirements Cellular networks
   ‌ISO 13485‌ Medical device compatibility MRI and surgical systems
6. ‌Cost vs. Performance Tradeoffs‌
   Budget Tier Cable Recommendation Typical Use Case
   ‌Low Cost‌ RG-58 or RG-174 IoT sensors, amateur radio
   ‌Mid-Range‌ LMR-400 or Times Microwave LMR Cellular DAS, Wi-Fi 6E
   ‌High Performance‌ Semi-rigid (W. L. Gore) Satellite payloads, 6G R&D
7. ‌Testing and Validation‌
   ‌VNA Testing‌: Measure S-parameters (S11/S21) to verify impedance match and loss.
   ‌Time-Domain Reflectometry (TDR)‌: Detect impedance discontinuities.
   ‌Environmental Stress Testing‌: Thermal cycling (-65°C to +150°C) and 20 g vibration per MIL-STD-810.
8. ‌Future Trends in High-Frequency Cables‌
   ‌Terahertz Cables‌: Sub-0.3mm coaxial lines with air-core dielectrics for 6G (275 GHz+).
   ‌Smart Cables‌: Embedded fiber Bragg gratings (FBG) for real-time strain monitoring.
   ‌Sustainable Materials‌: Recyclable LCP and bio-based FEP dielectrics.