Cardiac Catheter Cable Assemblies

Ultra-fine micro coaxial cables for cardiac catheters — IVUS, EP mapping, ICE, and ablation. 44–50 AWG, OD from 0.19 mm, 19-strand rope-lay for 1M+ flex cycles. Hybrid constructions with >60 dB isolation. ISO 10993.

Ultra-Fine Gauge × Ultra-High Core Density

ePTFE Low-Loss Dielectric Technology

Dual-Layer Shielding — Channel Isolation >40 dB

High-Flex — 1M Flex / 5M Torsion Cycles

ISO 9001 Certified · Fast Turnaround · Full Customization

Phase Matching ±1% — 100% TDR Verified

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Cardiac catheters place the most extreme miniaturization demands on signal cables. A coronary IVUS catheter shaft may have an internal diameter of just 0.9–1.1 mm — where standard 42 AWG micro coax (0.48 mm OD) is physically too large. Cardiac catheter cables require 46 AWG (0.30 mm), 48 AWG (0.24 mm), or 50 AWG (0.19 mm) with 19-strand rope-lay conductors for over 1 million flex cycles at the tight bend radii encountered in coronary anatomy.

We manufacture catheter-grade Micro Coaxial Cable assemblies for four primary cardiac catheter Applications : intravascular ultrasound (IVUS), electrophysiology (EP) mapping, intracardiac echocardiography (ICE), and hybrid ablation catheters combining imaging with therapeutic RF energy delivery.

Cardiac Catheter Applications

IVUS (Intravascular Ultrasound)
Coronary and peripheral IVUS catheters image vessel wall morphology and plaque composition at 20–60 MHz. Mechanical rotary IVUS uses a single transducer element on a rotating drive cable; solid-state IVUS uses 16–64 element phased arrays. Both require ultra-fine coaxial cables within catheter shafts of 2.6–5.5 French.
Cable spec: 46 AWG (16-element array fits 1.4 mm bundle OD in 5.5 Fr shaft), 50 Ω, 19-strand for rotary flex, PFA jacket, ISO 10993 biocompatible.
Critical parameter: Attenuation ≤ 4.5 dB/m at 60 MHz over 150 cm catheter length (total loss ≤ 6.75 dB — within IVUS receiver dynamic range of 40–60 dB).

EP Mapping and Ablation
High-density electrophysiology mapping catheters use 20–64 electrodes to map cardiac electrical activation patterns. Combined mapping-ablation catheters integrate RF energy delivery (up to 50W at 500 kHz) alongside diagnostic signal channels. The cable must maintain > 60 dB isolation between signal and power conductors.
Cable spec: 46–48 AWG coaxial (signal) + 28 AWG stranded (RF power) in hybrid construction, 7–8 French shaft, PFA jacket.
Critical parameter: Signal-to-ablation isolation > 60 dB from 100 kHz to 1 MHz.

ICE (Intracardiac Echocardiography)
ICE catheters place a 64–128 element phased-array ultrasound transducer inside a steerable 8–10 French catheter for real-time cardiac chamber imaging. This is the highest channel-density catheter application — 64 individually shielded coaxial elements must fit within a 3.3 mm internal diameter alongside steering wires.
Cable spec: 44–46 AWG, 64-core bundle at 3.0–3.4 mm OD, phase-matched ±1%, steerable catheter compatible.
Critical parameter: 64-channel bundle OD must be ≤ 3.0 mm (at 46 AWG) to fit 10 Fr catheter with steering mechanism.

EUS Catheter (Endoscopic Ultrasound via Catheter)
Catheter-mounted miniature ultrasound transducer (32–64 elements) passed through the working channel of a standard endoscope for GI tract imaging at 5–20 MHz. Smaller than ICE but similar cable architecture.
Cable spec: 44–46 AWG, 32–64 ch, 2.4–3.0 mm bundle OD, flexible for endoscope channel navigation.

Why Cardiac Catheters Require 46–50 AWG

The physics is straightforward: catheter shaft internal diameter constrains the cable bundle diameter, which constrains the individual cable OD, which determines the AWG.

Element Count	42 AWG Bundle OD	44 AWG Bundle OD	46 AWG Bundle OD	48 AWG Bundle OD
1 (rotary)	0.48 mm	0.38 mm	0.30 mm	0.24 mm
8	1.7 mm	1.3 mm	1.1 mm	0.9 mm
16	2.3 mm	1.8 mm	1.4 mm	1.1 mm
32	3.8 mm	3.0 mm	2.4 mm	1.9 mm
64	5.4 mm	4.3 mm	3.4 mm	2.7 mm

A 5.5 Fr IVUS catheter has approximately 1.83 mm internal diameter. After subtracting the guidewire lumen (0.36 mm) and catheter wall clearance, available space for the cable bundle is approximately 1.2–1.4 mm. Only 46 AWG (1.4 mm for 16 elements) or finer can fit.

A 10 Fr ICE catheter has approximately 3.3 mm internal diameter. After subtracting steering wires and catheter wall, available space is approximately 2.8–3.0 mm. A 64-element bundle at 46 AWG (3.4 mm) is tight; 44 AWG (4.3 mm) is impossible. Achieving 64 channels in 10 Fr is a frontier application requiring 46 AWG minimum and careful bundle geometry optimization.

Specifications by AWG Grade

Parameter	44 AWG	46 AWG	48 AWG	50 AWG
Conductor diameter	0.051 mm	0.040 mm	0.032 mm	0.025 mm
Cable OD	0.38 mm	0.30 mm	0.24 mm	0.19 mm
Impedance	50 Ω ± 2 Ω	50 Ω ± 2 Ω	50 Ω ± 2 Ω	50 Ω ± 3 Ω
Capacitance	≤ 110 pF/m	≤ 125 pF/m	≤ 140 pF/m	≤ 160 pF/m
DC resistance	≤ 3,490 Ω/km	≤ 5,580 Ω/km	≤ 8,900 Ω/km	≤ 14,200 Ω/km
Loss at 20 MHz	1.2 dB/m	1.8 dB/m	2.5 dB/m	3.5 dB/m
Loss at 60 MHz	3.2 dB/m	4.5 dB/m	6.2 dB/m	8.5 dB/m
Flex life (19-strand)	> 1M at 10 mm	> 1M at 8 mm	> 800K at 6 mm	> 500K at 5 mm
Yield rate	> 98%	92–96%	85–90%	75–85%
Lead time	Stock	4–6 weeks MTO	5–7 weeks MTO	6–8 weeks special
Cost relative to 44	Baseline	+80–120%	+200–300%	+400–600%

Decision guide: Use 44 AWG for ICE (64 ch in large catheter). Use 46 AWG for most IVUS and EP mapping (best balance of miniaturization and yield). Use 48 AWG only when 46 AWG is physically too large. Use 50 AWG only for extreme miniaturization in sub-3 Fr catheters where no other option fits.

Hybrid Cable Construction for EP Ablation

EP mapping-ablation catheters combine diagnostic signal channels with therapeutic RF power delivery in a single catheter shaft. This creates a unique cable engineering challenge: maintaining > 60 dB isolation between micro-watt signal channels and 50-watt RF power at close physical proximity.

Element	Spec	Function
Signal coaxial	46–48 AWG, 50 Ω, ePTFE, individual shield	EP signal acquisition
RF power conductor	28 AWG stranded Cu, FEP insulated	Ablation energy delivery (500 kHz)
Thermocouple pair	36 AWG Type T or Type K	Tip temperature monitoring
Irrigation lumen	PTFE tube, 0.5 mm ID	Irrigated-tip cooling
Steering wires	SS or NiTi, 0.15 mm	Catheter articulation
Strength member	Aramid yarn	Tensile load relief

Our hybrid construction uses a radial layer arrangement: signal coaxials in the center core (lowest EMI exposure), surrounded by a foil barrier shield, then power conductors in the outer layer. This geometry achieves > 65 dB signal-to-power isolation measured at 500 kHz — exceeding the 60 dB minimum required for artifact-free EP mapping during ablation.

Frequently Asked Questions

What is the smallest available IVUS cable?

50 AWG at 0.19 mm OD — a single coaxial element thinner than a human hair. For most IVUS catheter designs, 46 AWG (0.30 mm) is the optimal choice: it provides sufficient miniaturization for 5.5 Fr catheters while maintaining production yield rates of 92–96%. At 50 AWG, yield drops to 75–85% and cost increases 4–6× versus 46 AWG.

Can you phase-match catheter-grade cables?

Yes. Phase matching at 46 AWG uses the same TDR-based process as 42–44 AWG: measure every cable, sort into ±0.25% bins, assemble and verify. The higher sensitivity of 46 AWG to dielectric wall thickness variation requires tighter extrusion control, but ±1.0% phase matching is a standard production capability at this gauge. ±0.5% is available as a premium option.

How does your catheter cable compare to Junkosha or Proterial?

Our 46 AWG matches Junkosha MCT-300 and Proterial 46 AWG on all published parameters: conductor diameter, cable OD, impedance, dielectric material, VoP, and flex life. Key advantages: lead time 4–6 weeks (vs. 12–20 weeks), MOQ 500 m (vs. typically 5,000 m), and pricing 30–45% lower at equivalent specification. For catheter development programs, this means faster design iteration cycles.

Do you support ISO 13485 qualification?

We are ISO 9001:2015 certified. For customers requiring ISO 13485-qualified suppliers, we provide the full documentation package (CoC, test records, material certificates, traceability) that supports your ISO 13485 incoming material qualification process. We are actively pursuing ISO 13485 certification.

Solid or stranded conductor for disposable IVUS?

Solid conductor. A disposable IVUS catheter sees 1–5 procedures (10–50 insertions). Solid conductor flex life exceeds 100,000 cycles — far more than needed. Solid costs 40–60% less, has tighter impedance tolerance (±1.5 Ω vs. ±2.0 Ω), and eliminates the strand breakage risk during connector termination. Reserve 19-strand for reusable devices.

Developing an IVUS, ICE, EP, or ablation catheter? Share French size, channel count, operating frequency, and lifecycle — we will specify the optimal AWG and construction.

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Related words: Cardiac Catheter Cable, Ivus Cable, Ep Mapping Cable, Intravascular Ultrasound Cable, Ice Catheter Cable, Ablation Catheter Cable, Fine Wire Catheter Cable 46 Awg, Ep Catheter Coaxial Cable, Cardiac Imaging Cable, Interventional Cardiology Cable

Applications

Ultrasound Probe & Transducer

Modern 3D ultrasound probes contain 128–512 piezoelectric elements requiring precisely matched electrical path lengths for accurate beamforming. Multi-core micro coaxial cable provides per-channel shielding with phase-matched construction, serving as the core interconnect for GE, Philips, Siemens, and Mindray platforms.

Medical Endoscope Camera

Endoscope insertion tubes of 2–4 mm diameter must transmit HD/4K video while enduring 1M+ flex cycles. Using 42–46 AWG stranded conductors, OD achieves as small as 1.2 mm, supporting HD-SDI and 4K LVDS signals while meeting ISO 10993 biocompatibility requirements.

Robotic Surgery Cable

Robotic surgery arms must carry imaging signals, electrosurgical RF power, motor drive currents, and fiber optic illumination through ±270° articulating joints — all within a single hybrid assembly. Micro coaxial elements serve as the signal core, qualified to 5 million torsional flex cycles.

NDT Ultrasonic Testing (PAUT / TOFD)

Weld inspection and corrosion mapping in petrochemical, nuclear, and aerospace industries use PAUT and TOFD — requiring 16–256 core, phase-matched ±1%, 50 Ω micro coaxial bundles with industrial PUR/FEP/PTFE jackets, compliant with ASME V and EN 583-2 standards.

MRI-Compatible Device Cables

The MRI bore presents three electromagnetic environments requiring all metals to pass ASTM F2503 ferromagnetic assessment. Non-magnetic silver-plated copper alloy conductors meet 1.5T/3T MRI safety requirements for MRI-guided interventions, coil connections, and CT detector array interconnects.

Semiconductor / Industrial Robotics / Aerospace

Semiconductor wafer AOI inspection, industrial robot joint routing, and aerospace sensor arrays all demand high-density, fine-gauge cables with tight impedance control and signal integrity — areas where micro coaxial cable delivers unmatched performance in high-frequency transmission, channel isolation, and compact construction.