Bundled Micro Coaxial Cable

A bundled micro coaxial cable is an assembly of multiple individually shielded 50 Ω micro coaxial elements — typically 42 or 44 AWG — combined into a single flexible harness with a common outer jacket. Each element maintains its own aluminum-polyester foil and silver-plated copper braid shielding throughout the bundle, providing per-channel isolation exceeding 40 dB at 10 MHz. This per-element shielding is what distinguishes bundled micro coaxial cable from ribbon cable, twisted-pair, and FPC alternatives.

We manufacture bundled micro coaxial cable assemblies from 32 to 512 cores for ultrasound probe manufacturers, NDT phased-array equipment builders, endoscope OEMs, and research institutions. Phase-matched bundles (±1.0% standard, ±0.5% aerospace/premium) are our core production capability — over 70% of our bundled micro coaxial output is phase-matched.

Standard Configurations

Technical Specifications — Per Element

Bundle Construction

Layer 1 — Individual Micro Coaxial Elements
Each element is a complete 50 Ω coaxial cable: center conductor → ePTFE dielectric → aluminum-polyester foil → silver-plated copper braid → FEP/PFA jacket. Color-coded jackets enable element identification during connector termination.

Layer 2 — Concentric Layer Arrangement
Elements are arranged in concentric layers following standard cabling geometry: 1-6-12-18-24-30 pattern (hexagonal close-pack). A 128-element bundle has 7 concentric layers; 256 elements has 9 layers; 512 elements has 13 layers.

Layer 3 — Binding and Serving
Kevlar aramid yarn or PTFE tape wrap binds the concentric layers, controlling inter-element spacing and preventing element migration during flex. Binding tension is calibrated to allow controlled element slip (necessary for flex life) while preventing bundle loosening.

Layer 4 — Overall Shield (Optional)
For Applications requiring additional EMI protection at the bundle level, an overall foil + braid shield can be added over the bound core. Adds approximately 0.5–1.0 mm to bundle OD.

Layer 5 — Outer Jacket
PVC (general purpose), PUR (industrial flex), PFA (medical/high-temp), or FEP (cost-optimized). Jacket wall thickness: 0.3–0.8 mm depending on material and application.

Phase Matching Process

Step 1 — Dielectric Extrusion Control
ePTFE dielectric wall thickness held to ±0.005 mm across the entire production lot. Wall thickness directly controls Dk uniformity, which determines propagation velocity consistency.

Step 2 — Individual Cable TDR Measurement
Every cable element is TDR-measured for propagation delay (ps/m) and impedance profile at incoming inspection before bundle assembly. Data logged per cable serial number.

Step 3 — Bin Sorting
Cables are sorted into bins of ±0.25% propagation delay tolerance. Cables outside the bin tolerance are diverted to non-matched orders (not scrapped — used for unmatched bundles or Applications where phase matching is not required).

Step 4 — Bundle Assembly from Matched Bins
Elements from a single bin are assembled into the bundle. Position mapping records which cable serial number occupies which position in the concentric layer arrangement.

Step 5 — Completed Bundle Verification
TDR re-measurement of every channel in the completed bundle. Verify compliance with ±1.0% (standard) or ±0.5% (premium) specification. Any channel outside tolerance is replaced and the bundle re-verified.

Step 6 — Per-Channel TDR Certificate
Certificate documents: cable serial number, bundle position, measured propagation delay (ps/m), impedance, deviation from mean. Shipped with every phase-matched bundle at no additional charge.

Applications

Medical Ultrasound Probes
The largest market for bundled micro coaxial cable. 128–512 channel phased-array probes for cardiac, abdominal, OB-GYN, vascular, and TEE imaging. Phase matching mandatory for beamforming accuracy. Compatible with GE, Philips, Siemens, Mindray platforms.

NDT Phased Array (PAUT)
32–256 element bundles for weld inspection, corrosion mapping, aerospace composite testing. Phase-matched ±1% for accurate beam steering. LEMO EPL connectors. ASME/ASTM documentation.

Medical Endoscopy
6–64 core bundles for HD/4K chip-on-tip video. Bundle OD from 1.8 mm at 44 AWG. PFA jacket for autoclave compatibility. ISO 10993 biocompatible.

Intracardiac Echocardiography (ICE)
64-channel bundles at 44–46 AWG for 8–10 Fr steerable catheters. Phase-matched for real-time cardiac imaging.

Research and Development
Custom core counts, non-standard AWG, experimental configurations for university labs and R&D programs. Low MOQ (5 assemblies).

Frequently Asked Questions

What is the difference between bundled micro coaxial cable and multi-core coaxial cable?

The terms are interchangeable. "Bundled micro coaxial" emphasizes the construction method (individual elements bundled together). "Multi-core coaxial" emphasizes the core count. Both refer to assemblies of multiple individually shielded 50 Ω coaxial elements in a common harness. Industry usage varies by region and application sector.

What is the standard AWG for ultrasound probe bundles?

42 AWG for 128–256 channel standard probes. 44 AWG for 256–512 channel high-density 3D/4D probes. 42 AWG is the workhorse — lower cost, faster delivery (stock), adequate for the majority of clinical probes. 44 AWG is chosen when bundle OD must be minimized for ergonomic or channel-density reasons.

How does phase matching affect cost?

Phase matching adds approximately 15–25% to assembly cost versus unmatched bundles. The cost comes from: individual TDR measurement of every cable element, bin sorting (some elements fall outside tolerance), completed bundle verification, and per-channel certificate generation. For ultrasound and PAUT applications, this cost is mandatory — unmatched cables produce measurable degradation in image quality or defect detection capability.

Can I order unmatched bundles for non-imaging applications?

Yes. Unmatched bundles use the same cable elements but skip the TDR sorting and verification steps. Available at 15–25% lower cost with faster delivery. Suitable for data transmission, sensor arrays, and other applications where per-channel propagation delay uniformity is not critical.

What connector termination is available?

I-PEX (Cabline series & ZIF series), ITT Canon, HIROSE (DF series), LEMO (00, 01, EPL multi-pin), BNC, Microdot, custom overmold, and bare-end. Connector selection depends on application: I-PEX/HIROSE for ultrasound probes, LEMO EPL for NDT PAUT, BNC for lab/research. We terminate at our facility as part of the cable assembly service.

What is the minimum bend radius for a 256-channel 42 AWG bundle?

Recommended minimum bend radius: 10× cable OD = 10 × 9.6 mm = 96 mm for static routing. For dynamic flex (repeated bending): 20× cable OD = 192 mm. Using 19-strand conductor construction allows tighter bend radius: 7× OD static, 15× OD dynamic

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