Over the last 25 years, Meridian Cable has been a leading provider of custom cable assemblies, wire harnesses, and more. Our commitment to quality and high-end materials makes our cables superior to an off-the-shelf cable solution. We apply these standards to everything we do, including our custom coaxial cable assemblies. We pay attention to ultra-fine details and labor-intensive processes to create coaxial cable solutions to the highest industry standards.
We build custom coaxial cable assemblies from the ground up. From the meticulous design stage of production to the final product, our team has eyes on your cable solution. Every coaxial cable assembly we build has undergone a heavily involved process before it is ready for mass production. With a list of industry-recognized certifications in quality, we continuously strive to create quality, dependable products.
What is a Coaxial Cable Assembly?
Coaxial cables are electrical cables with a central conductor surrounded by insulation, shielding, and an outer jacket. The term coaxial comes from the central conductor and the shielding sharing a single geometric axis.
A coaxial cable is used to transfer high-frequency electrical signals, data, and pulses of electricity with little to no loss. Because of the interwoven shielding surrounding the conductor, the cable is protected from electromagnetic interference (EMI). This protection makes coaxial cables excellent for electronically noisy environments.
Coaxial cable assemblies are used in various industries and applications. You have likely seen a coaxial cable connecting to your home TV or sound system. Because they operate so well in environments with heavy EMI, coaxial cables are often seen in visual or audio industries, telecommunications, or industrial switchboards. These highly capable cables are the workhorse of a myriad of electronic connections.
The Design Phase for Custom Coaxial Cable Assemblies
We make working with Meridian to design a custom coaxial cable assembly an easy and straightforward process. Our team of in-house engineers has some of the best minds in the industry. With multiple decades of experience, our design team is thoroughly equipped to guide you through the entire process. From the conductor extrusion to the final product, our engineers will closely monitor your cable’s progress.
Because the design team will be responsible for laying the foundation of your cable solution, they will work directly with our clients to determine exactly what they will need. We’ll help you find the ideal cable solution that is customized just for your equipment. While you certainly could find any old cable from an electronic store, you may not get exactly what you need. Our process ensures that your cable solution from Meridian is specifically created for you. Plus, our manufacturer's warranty gives you the peace of mind to trust in our team and products.
If you are unsure of what you need, our crew can help you figure it out. Our full-scale cable design and engineering services include creating a one-of-a-kind cable solution for any equipment or industry. You can trust our team with any custom coaxial cable assembly needs.
Building Custom Coaxial Cable Assemblies
When it comes to creating custom coaxial cable assemblies, attention to the little details matters most. After the design phase is complete, we extrude the conductor to the precise size you need for your equipment. This process takes the raw metallic material (typically copper) and transforms it into a long thin strand. Doing this with accuracy is an essential part of the overall quality of our cables.
Custom Conductor Sizes
The conductor size will determine the capacity of your cable to transfer high-frequency signals. Though a larger conductor size will be able to handle larger amounts of signal, there is a limit to how large it can be and remain effective. Depending on your equipment, the conductor size will need to be tailored to ensure proper functionality. A coaxial cable assembly with incorrect conductor sizes could spell disaster for your gear. That’s why precision and accuracy are vital for extruding cables.
Having the proper conductor size for your equipment allows for the transfer of signal and data as it should. If you need help determining the correct size conductor your equipment requires, our team can guide you through the design process.
At Meridian, we take pride in our work and ability to custom-design cable solutions for all applications. The conductor size in a coaxial cable assembly can be anywhere from as large as 12 gauge all the way down to 34 gauge. Of course, your equipment may require multiple conductor sizes in separate cables to connect properly. We can easily add this to the design of your custom coaxial cable assemblies.
Custom Conductor Materials
The most common conductor type is copper, but we can customize your conductor to best suit your equipment. By infusing a rare metal into the coaxial cable conductor, you may have improved transfer capacities, a faster transfer, or optimized the cable for the technology you use in your industry. We can add an alloy to the design of the cable or leave it as a copper conductor, depending on your specific needs.
Once the conductor is complete, every coaxial cable will need a layer of insulation. The insulation in a cable serves two primary purposes. The first purpose of insulation is to act as a physical barrier for the conductor. This helps to protect the conductor from outside elements while keeping it snugly in place in the cable. This protective barrier helps keep the conductor safe from hazards like heat, kinks, and impact.
The second function of the insulation is to keep the flow of electricity where it should be. By holding the high-frequency signals in, the insulation ensures the cable efficiency and the flow of electricity are maintained. The cable can function correctly and efficiently with the two-fold protection that the insulation provides.
We offer several material options for insulation to best fit your set-up. Depending on the purpose and type of equipment you have, some insulation materials may be a better fit than others. We can create insulation for coaxial cable assemblies out of any of the following materials:
- Natural rubber
No matter what your specific equipment requires, we have options to make the ideal coaxial cable assembly just for you.
An essential component in any coaxial cable assembly is the shielding layer. While the insulation protects the conductor from internal and external hazards, the shielding is designed to defend against external electrical threats such as EMI. The shielding protects the inner cable by deflecting and grounding EMI that may damage or destroy the signal. The shielding ensures a secure connection and safe data transfers within the cable by keeping this interference away from the conductor.
The shielding within a coaxial cable is a braided layer of thin metal that surrounds the insulation layer. This design is cylindrical in nature and gives the cable a well-fortified defense against EMI. The woven shielding also provides more flexibility than spiral or solid shielding. By wrapping the insulation and conductor in the woven shield, the coaxial cable will become naturally coiled in tight concentric circles.
The security and flexibility shielding provides for coaxial cables make them well-suited for electronically noisy environments and industries.
The penultimate step in the production process is to add the outermost layer, known as the jacket. At this production stage, your coaxial cable assembly has the conductor, insulation, and shielding. Adding the jacket onto the coaxial cable is more than just wrapping it all up. The jacket on a cable is the final layer of protection for the inner cable. The jacket is a vital part of the cable by defending against elements like moisture, impact, or other outside hazards.
The suitable jacket material can make all the difference regarding the cable’s purpose. Depending on your equipment, the jacket can be chosen to maximize flexibility, durability, functionality, and longevity. We offer a range of jacket materials that can be selected to fit your system perfectly.
Bringing it all Together
Once the cables have been produced, the final stage is to bring them together in the custom coaxial assemblies. We make the cables and assemblies from scratch and take the time necessary to ensure everything functions correctly. Once complete, we keep your design on file, so reordering is simple and quick.
If you are ready to get completely customized coaxial cable assemblies made for your business, contact our team to request a quote today.
Let Meridian Cable Build Your Custom Coaxial Cable Assembly
Meridian Cable is proud to be a leading manufacturer of cable assemblies with decades of experience. Our in-house engineers work with you throughout every step of the design and prototyping process to ensure that your custom cable assembly is perfect for your project. Contact our team to get started today.