One thing is sure when creating top-notch, UL-certified RF cable assemblies: attention to the smallest details matters. For over 25 years, Meridian Cable has been committed to quality manufacturing standards and to attending to the finest details. We’ve got some of the most brilliant minds in the industry on our in-house engineering team to help design, prototype, test, and manufacture custom RF cable assemblies for industries all over the globe. 

Our decades of experience and commitment to outstanding work in our field means that you get a cable assembly you can depend on. We build entirely custom RF cable solutions to the most exacting detail. We’ll cover everything you need to know to start your custom RF cable assembly project with our team.

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Custom RF Cable Assemblies

Designing and producing RF cable assemblies is not just about piecing together the right elements—it's about creating a work of art that delivers high-performing transmission and reliability day after day. When we develop our custom cables, we take our dedication to quality seriously and remain committed to being one of the world's leading cable manufacturers of our time. Our multiple decades of experience, acute attention to detail, and impeccable track record help us design and produce some of the best custom RF cable assemblies on the market.

Although you have countless options for off-the-shelf solutions, nothing compares to a custom product built to your exact specifications and transmission needs. We take into account the fine details of every project to produce something we can be proud of—RF cable assemblies that get the job done and shatter all expectations.

What is an RF Cable Assembly?

Also known as a coaxial cable, an RF cable is a standard cable used to transmit visual and audio signals. An RF cable is typically identified by its connectors which have a single pin in the center of the connector. This pin inserts into the dock while the surrounding connector encompasses the outside of the dock. This design allows RF cables to connect securely while blocking out potential interference. These powerful cables are used in any industry that utilizes visual or audio equipment so that they can be found in an array of outlets. 

In the days of cable television, RF cables were seen in nearly every home. Now, while not used as frequently for home televisions, RF cable assemblies are a significant component for countless applications.

The cable assemblies used in electronically noisy areas need to be protected from EMI. EMI can significantly impact the effectiveness of data transmission using cable assemblies. By interfering with the cable assemblies’ ability to transmit data effectively, EMI can be a severe issue for an unshielded cable assembly. While a cable's insulation and jacket helps protect the conductors from moisture, breaks, and kinks, they do not protect from any type of EMI.

Working with the Experts on All Things Custom Cables 

From the moment you contact our team, you'll recognize the difference that working with an expert can make. Our knowledgeable team helps you with clear, step-by-step guidance throughout your entire order experience. Whether you need a single RF cable assembly or require a mass production order, we are the cable manufacturers that help you get there.

The real difference our engineers can make is the unparalleled expertise they bring to the table. With multiple decades of experience between them, our engineers represent a wealth of knowledge in creating and crafting bespoke cable solutions for every industry and purpose. Their vast knowledge base makes all the difference in the world when it comes to RF cable manufacturing. 

Think about it: if you could have an expert design your car or house, considering every tiny detail and building it to meet your exact needs, wouldn't that be awesome? That's exactly what we do when we build a custom RF cable or RF cable assembly for you. We build something that meets your exact needs, from transmission and signal capacity to durability and environmental protective elements. 

We believe the best solution is one that is designed specifically for your needs; that's why we offer full-scale design and engineering services to deliver a precision, high-performing product just for you. Our team will help you build your RF coaxial cable assembly from the ground up, taking into account every detail and specification.

Tried and True: How We Test Every Product We Craft

As one of the world's leading cable manufacturers, we believe our customers deserve a higher quality product that not only does the job but goes above and beyond to ensure durability and reliability. We don't just splice the elements of an RF coaxial cable assembly together and hope for the best—we put each and every product through a series of rigorous and intense tests in our state-of-the-art testing lab. 

By the time a product reaches your doorstep, you can bet it's been poked, prodded, tested, and proven to pass every type of examination we can throw at it. We thoroughly examine each product to ensure its functionality, capacity, quality, durability, and reliability, so you don't have to worry about anything. We do all the quality tests ahead of time, providing a seamless integration into your system without any hiccups or surprises. 

Once you receive your RF coaxial cable assembly, you're able to plug and play right away! Plus, we've already worked out the design flaws during the initial digital rendering phase, ensuring your cable is ready to rock and roll from the day it arrives.

Advantages of Custom RF Cable Assemblies

These capable cable assemblies have a lot to offer for radio, television, music industries, and more. Because of their simple-to-use design, RF cable assemblies are easy to install. This clever design also makes them easy to extend with a coaxial extender. Additionally, RF cable assemblies are known for their durability and longevity. Because they are often used with heavy sound or TV equipment, durability comes in handy. 

Another benefit of RF cable assemblies is they have excellent resistance to electromagnetic interference (EMI). When used in electronically noisy environments, the inner shielding helps block out interference that could damage or destroy the transmitted signal. EMI can be the death of data if a cable is not properly shielded. 

Lastly, when Meridan designs and builds your RF coaxial cable assemblies, you can rest easy knowing that expert engineers oversee every detail. Our design team completely customizes your cable solutions so you get a tailor-made product. Sure, you could get some off-the-shelf products from any electronic store that may do the bare minimum of the job. But then you run the risk of getting something that doesn’t quite fit your individual needs. At best, a one-size-fits-all solution will barely get the job done. At worst, a poorly manufactured cable could bring down your whole system. It is far better to know that your cable solution is made just for your equipment and that it is held to the highest manufacturing standards. 

Here at Meridian Cable, we stand behind every custom RF cable assembly we manufacture. Our commercial warranty guarantees that our products will be free of manufacturing and material defects. We believe in our products and strive to create the best quality for our customers. You can trust our expert team to design, prototype, test, and manufacture top-notch cable solutions for your business.

RF Cable Assemblies You Can Count On: Our Incredible Warranty

Some companies are content to deliver a product that may or may not be everything you need it to be, but not us! We stand behind our products and back all custom cables we produce with a reliable commercial warranty. In other words, when you trust Meridian as your custom cable manufacturer, you don't have to worry about manufacturing defects or ineffective products. We operate under a simple yet timeless operational standard—to make products we can be proud of. That's it. 

We strive for excellence in everything we do, so our warranty is just the icing on the cake. We like to take care of our customers and treat them like family, so we're always here to support and help you through any cable-related issues we can.

Building a Custom RF Cable Assembly

When we create custom cable assemblies, wire harnesses, or any of our other products, it’s important to start with the conductor. By working from the conductor out, our design team can build a precise cable to suit your unique needs. From the core to the outer jacket, you have options every step of the way to design the ideal RF cable solution for your business. 

When we say that we have our eyes on every step of the process, that’s exactly what we mean. We start by extruding the conductors from raw materials. This means we can closely monitor the process to ensure quality and accuracy. We’re proud to have and maintain our ISO 9001 certification, in addition to a host of other industry-recognized certifications for our near-fanatical commitment to quality. 

Each product we build undergoes a lengthy, labor-intensive process before it is ready to mass produce. We take quality seriously and thoroughly test each product to ensure that it is capable, holds up to industry standards, and performs excellently. When a custom RF cable assembly is ready for mass production, it has been repeatedly tested for durability, functionality, and quality. We do this to guarantee that our products are precisely what our clients require in a cable solution. 

Custom Conductor Size

Because the conductor is the critical component for transmitting a signal, it is important to ensure it will have the necessary capacity. The appropriate conductor size can make all the difference in custom RF cable assemblies. The intended use for the cable assembly and your equipment will determine what size conductor you need. In the initial design process, you will work with our in-house engineering team to help you get the ideal conductor size for your system. 

While we can create a wide range of conductor sizes, don’t let the specifics overwhelm you. Our team will help you determine precisely what you need for your audio or visual equipment. Typically, we offer conductor sizes ranging from 34 gauge to 12 gauge. Different sizes can be combined within an assembly to make the perfect connection. 

Insulation

Once the conductor is finalized, custom coaxial cable assemblies need a layer of insulation. Insulation in an RF cable serves to help protect the conductor from outer elements and hazards. Keeping the innermost layer covered is essential to ensure the successful operation of the cable assembly. If the conductor is compromised, kinked, or unprotected, it will perform poorly or potentially damage equipment. 

The insulation also serves a secondary purpose in holding the frequency within the cable. Acting as a barrier for the electronic pulses in the conductor, the insulation keeps the flow of electricity where it should be. This ensures proper function and safe operation. 

We offer several options for insulation material to best fit your equipment. While each material will perform a similar task, your equipment may require a specific material. You may also select a different insulation material to work better with your system or to improve durability. No matter what you need, we have you covered for all custom RF cable assembly applications. 

 

You can select insulation materials from any of the following:

  • PVC
  • PE
  • PP
  • Teflon
  • Natural rubber

Customizable Conductor Material

While typical RF cable conductors are made from copper, we can customize your conductors with rare metals to suit your equipment. Depending on your equipment, adding an alloy or mixed metal can boost the cable’s capacity and optimize performance. Not all sound or tech gear will require additional materials, but we can accommodate whatever you need.

Shielding

The all-important shielding is next to the final layer in custom RF cable assemblies. RF coaxial cables are known for their resistance to EMI and are an industry standard for this feature. The shield layer blocks EMI from messing with the conductor and scrambling the signal. In that sense, shielding is just what it sounds like. But proper shielding is more than mere defense. As the shield blocks out the EMI, it also grounds it to disperse it securely. This two-fold action is exactly the protection a conductor needs to operate successfully. 

In most designs, the shield layer for RF cable assemblies is thin strips of copper braided into a woven tube. This braided design effectively helps block EMI's danger while allowing the cable flexibility to be coiled into concentric loops. This will give you the protection and flexibility to move and connect your RF cables as your equipment requires. With the security shielding provided, your RF cable is intended to be durable and withstand harsh audio and visual work conditions.

Final Layer: Adding a Jacket

Once the previous steps have been completed, it’s time to add the jacket around the outside. The jacket is the outermost protection for an RF cable. It can be made from a range of materials and serves to hold everything together. This final step in the design process is what will protect the inner parts of the cable assembly from moisture, dirt, and debris. Depending on your equipment and environment, you can select a jacket material to optimize durability, flexibility, or longevity. 

Once the jacket is selected, your design for custom RF cable assemblies is complete. We will then move on to the prototyping and testing phases of production.

In most designs, the shield layer for RF cable assemblies is thin strips of copper braided into a woven tube. This braided design effectively helps block EMI's danger while allowing the cable flexibility to be coiled into concentric loops. This will give you the protection and flexibility to move and connect your RF cables as your equipment requires. With the security shielding provided, your RF cable is intended to be durable and withstand harsh audio and visual work conditions.

The Meridian Cable Promise

 

When you need a cable assembly manufacturer, you want to ensure you're getting the best bang for your buck. In the end, you don't want an RF cable assembly that merely does the job, you need something that you can count on. That's where our unmatched experience and unfailing track record for excellence come into play. Our team of experienced designers and engineers have sharpened their skills over decades, ensuring your product is made by some of the most skilled hands on the planet. 

If you'd like to start a project of your own, our team is here to support you every step of the way. Reach out to us to get started on your custom RF cable assembly project today! 

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Industries We Serve

RF cable assemblies play a vital role across a multitude of industries that require consistent, reliable signal transmissions without harmful interference. Because of their usefulness in transmitting low voltage signals in visual and audio platforms, industries such as telecommunications, aerospace, and military defense rely heavily on RF cable assemblies in every shape and size. These custom cables are the backbone of countless electrical systems across these industries and more, delivering and maintaining strong data connections in high-performance environments. 

 

RF coaxial cable assemblies are frequently used in the medical arenas, ensuring precise signal delivery for critical diagnostic equipment. In areas that demand consistency and reliability, RF cable manufacturers must pay close attention to the most exacting details to ensure they operate as expected every day. Whether it's in a broadcast television setting or an industrial automation system, RF cable assemblies support a wide range of equipment and sectors. 

Well, we've created RF coaxial cable assemblies for countless sectors, some of the most frequent applications include:

  • Telecommunications, where consistent signal is an absolute necessity.
  • Industrial engineering applications that demand reliability and rigid attention to detail.
  • Military and defense, in which rugged durability is paramount due to potentially harsh environments.
  • In medical arenas, life-saving technology relies on RF cables to operate successfully and diagnose accurately. 
  • Network broadcasting industries demand continuous signal flow and strain on their equipment. 
  • And more! 

Industries such as these can rely on Meridian’s experts as dedicated wire and cable manufacturers with an impeccable track record of success and excellence.

In Your Hands Before You Know It!

We know some projects require urgency, so we offer unbelievably fast, quick-turn production to have your product in hand in record time. We've developed and perfected highly efficient production systems that take your RF cable assembly from concept to completion before you know it. We keep our production times short because we know how important it is to get what you need when you need it.

In addition to our rapid production times, we also simplify the integration process by tailoring a custom RF coaxial cable assembly to your specific equipment, environment, and functionality demands. Instead of undergoing a rigorous installation process, we've simplified your integration by delivering a product that is ready to roll as soon as it arrives. Fortunately for you, that means no messy or frustrating installation process once you receive your product. We do as much as we can to make your integration and installation as easy as possible, removing the hassle and frustration entirely.

Custom Extrusion & Molded Components

Because we like to keep a close eye on everything we build, we custom extrude our conductors, giving us precise control over the exact measurement and function of your cable. This means we can create something entirely for you that delivers a powerful performance no matter your equipment, environment, or industry. Particularly in sectors that demand specific signal strength and consistent flow, our custom extrusion process gives us extraordinary capabilities to produce precisely what you need. 

We pride ourselves on our ability to customize your product, and that includes custom molded components as well. Although some companies would have you believe that a one-size-fits-all solution will suffice for your needs, we simply don't abide by that. We're not afraid to build something just for you, even if it requires painstaking detail and rigorous testing. In fact, we appreciate the challenge of building something entirely from scratch. Plus, it doesn't hurt that we've collected an army of 3D printers and custom molding equipment to help craft 100% unique components for your cable assembly. 

Our ability to create unique conductor sizes and custom-molded components is one thing that sets us apart from the crowd. While others may offer semi-custom products, we deliver 100% bespoke RF cable assemblies that tick all the right boxes. With over 5,000 unique elements and components to choose from, you can bet we’ll be able to build the precise connection solution to your problem.