Multi-Core Coaxial Cable

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

The terms are interchangeable. "Multi-core" emphasizes high core count; "bundled micro coaxial" emphasizes the construction method. Both describe multiple individually shielded coaxial elements in one harness - the key technical characteristic being per-channel shielding. Industry usage varies by region: "multi-core coaxial" is more common in European NDT specifications; "bundled micro coaxial" is more common in Asian medical device manufacturing.

Q: Can multi-core coaxial cable be phase-matched?

Yes. TDR-measure every cable, sort into plus/minus0.25% bins, assemble and verify to plus/minus1.0% or plus/minus0.5%. Per-channel TDR certificate shipped with every phase-matched assembly. Phase matching is our core manufacturing capability - over 70% of our multi-core coaxial production is phase-matched.

Q: What core counts are available?

4 cores to 512 cores. Standard for ultrasound: 128, 192, 256, 288. For NDT PAUT: 32, 64, 128. For endoscopy: 6, 8, 16, 32, 64. Custom counts at same MOQ - 5 assemblies prototype, 50 production.

Q: What is the maximum frequency for multi-core coaxial cable?

Individual elements are rated to 6+ GHz. In bundled configuration, practical bandwidth depends on length and crosstalk budget. At 2 m length: > 3 GHz usable. At 5 m: > 1 GHz. For ultrasound (1-60 MHz) and NDT (0.5-25 MHz), bandwidth is never the limiting factor.

Multi-core coaxial cable with 32–512 individually shielded 50Ω cores (36–50 AWG). ePTFE dielectric, phase-matched ±1%. For ultrasound, NDT, endoscopy, and robotic surgery. Custom assemblies available.

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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Multi-Core Cable Assemblies

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Multi-core coaxial cable — also called multi coaxial cable, multi coax, or Bundled Micro Coaxial Cable — is an interconnect assembly in which multiple individually shielded 50 Ω coaxial elements are combined into a single flexible harness. Each element retains its own foil and braid shielding throughout the bundle, maintaining per-channel isolation exceeding 40 dB at 10 MHz. This is the fundamental distinction between multi-core coaxial cable and twisted-pair or FPC alternatives: every signal channel is independently shielded.

We manufacture multi-core coaxial assemblies from 32 cores to 512 cores, at gauges from 36 AWG to 50 AWG, with phase-matched or standard electrical specifications.

Technical Specifications

Parameter	36 AWG	40 AWG	42 AWG	44 AWG	46 AWG
Single cable OD	0.75 mm	0.57 mm	0.48 mm	0.38 mm	0.30 mm
Impedance	50 Ω ± 2 Ω (all gauges)
Dielectric	ePTFE (Dk ≈ 1.45, VoP ≥ 78%) (all gauges)
Conductor	Silver-plated copper alloy CuAg (all gauges)
Shield	Foil 100% + Ag-plated braid ≥ 82–88% (all gauges)
Capacitance	≤ 82 pF/m	≤ 90 pF/m	≤ 95 pF/m	≤ 110 pF/m	≤ 125 pF/m
DC resistance	≤ 880 Ω/km	≤ 1,390	≤ 2,195	≤ 3,490	≤ 5,580
Core count range	1–64	1–128	32–512	32–512	8–256

Bundle OD by Core Count

Core Count	42 AWG OD	44 AWG OD	46 AWG OD	Typical Application
32	3.8 mm	3.0 mm	2.4 mm	Endoscope, EP catheter
64	5.4 mm	4.3 mm	3.4 mm	Small endoscope, ICE
128	7.2 mm	5.8 mm	4.6 mm	Standard 2D ultrasound
256	9.6 mm	7.8 mm	6.2 mm	3D/4D ultrasound
512	13.7 mm	11.2 mm	8.8 mm	Next-gen matrix array

Multi-Core Coaxial vs. Alternatives

Parameter	Multi-Core Coaxial	Flat FPC	Twisted-Pair
Per-channel shielding	✓ Individual foil + braid	✗ Shared ground	✗ None
Crosstalk isolation	> 40 dB at 10 MHz	5–15 dB	20–30 dB
Frequency range	DC to 6+ GHz	DC to ~500 MHz	DC to ~200 MHz
Phase matching	±1% achievable	Not achievable	Not applicable
Impedance control	50 Ω ± 2 Ω per element	Uncontrolled	~100 Ω differential
Flex life	> 500K–1M cycles	10K–50K cycles	50K–200K cycles
Max core density	512 in 11 mm OD (44 AWG)	Limited by pitch	Limited by pair size
Cost per channel	Higher (shielded per element)	Lower (shared ground)	Moderate

How Multi-Core Coaxial Cable Is Constructed

A multi-core coaxial cable assembly begins with individual micro coaxial elements. Each element is a complete 50 Ω coaxial cable in miniature:

Layer 1 — Center Conductor: Silver-plated copper alloy (CuAg), solid or 7/19-strand rope-lay. Diameter ranges from 0.025 mm (50 AWG) to 0.127 mm (36 AWG).

Layer 2 — Dielectric: ePTFE (expanded polytetrafluoroethylene) with Dk ≈ 1.45, achieving velocity of propagation ≥ 78%. This low-Dk dielectric is the key to controlled 50 Ω impedance at sub-0.50 mm cable OD.

Layer 3 — Inner Shield: Aluminum-polyester foil wrap providing 100% optical coverage. Prevents high-frequency leakage.

Layer 4 — Outer Shield: Silver-plated copper braid at ≥ 82–88% optical coverage. Provides mechanical robustness and low-frequency shielding.

Layer 5 — Individual Jacket: FEP or PFA fluoropolymer, 0.015–0.025 mm wall thickness. Provides element identification (color coding) and handling protection.

These individual elements are then assembled into bundles of 32 to 512, arranged in concentric layers, bound with Kevlar or PTFE serving tape, and enclosed in a common outer jacket (PVC, PUR, PFA, or FEP depending on application).

Applications of Multi-Core Coaxial Cable

Medical Ultrasound
128–512 channel phased-array probes for 2D, 3D, and 4D imaging. Phase-matched ±1% for beamforming accuracy. Compatible with GE, Philips, Siemens, Mindray platforms. The largest single application for multi-core coaxial cable globally.

Industrial NDT (Non-Destructive Testing)
32–256 element phased-array ultrasonic testing (PAUT) bundles for weld inspection, corrosion mapping, and aerospace composite testing. TOFD matched pairs. LEMO EPL connectors. ASME V / ASTM E2491 documentation.

Medical Endoscopy
6–64 core bundles routed within flexible endoscope insertion tubes (OD 2.4–6 mm). HD/4K video signal via LVDS or HD-SDI protocol. Bundle OD from 2.4 mm using 44–46 AWG elements.

Robotic Surgery & Catheters
Signal harnesses within surgical robot arms requiring ±270° torsional flex to 5M cycles. IVUS and ICE catheter bundles at 46–50 AWG. Hybrid composite constructions combining coaxial signal, power conductors, and fiber optics.

MRI / CT / PET Imaging
Non-ferromagnetic multi-core coaxial for MRI receive coils (titanium/CuBe connectors, segmented shield). CT gantry slip-ring cables rated 5M+ torsional cycles. PET detector cables with > 85 dB shielding.

High-Speed Digital
Twinax differential pairs within multi-core bundles for USB 3.2, HDMI 2.1, DisplayPort. 100 Ω differential impedance, < 3 ps/m skew.

Phase Matching in Multi-Core Coaxial Bundles

Phase matching ensures all coaxial elements in a bundle have identical electrical propagation delay — critical for ultrasound beamforming and PAUT inspection. Our process:

Step 1: Extrude ePTFE dielectric with wall thickness controlled to ±0.005 mm, producing consistent Dk across the production lot.

Step 2: TDR-measure every individual cable for electrical length (propagation delay in ps/m).

Step 3: Sort cables into bins of ±0.25% electrical length tolerance.

Step 4: Assemble bundles from matched bins. Verify completed bundle to ±1.0% (standard) or ±0.5% (aerospace/premium).

Step 5: Issue per-channel TDR certificate documenting every element's measured propagation delay.

This process adds approximately 15–25% to cable cost versus unmatched bundles, but is mandatory for phased-array imaging and precision NDT.

Ordering Guide

To quote a multi-core coaxial cable assembly, we need:

1. Core count — How many individually shielded coaxial elements?
2. AWG gauge — 36, 40, 42, 44, 46, or 50 AWG?
3. Phase matching — Required? If yes, ±1.0% or ±0.5%?
4. Connector type — I-PEX, HIROSE, LEMO, BNC, ZIF, bare-end?
5. Cable length — Meters, tolerance?
6. Jacket material — PVC (general), PUR (industrial flex), PFA (medical/high-temp), FEP (cost-optimized)?
7. Application — Helps us recommend optimal construction.
8. Annual volume — Prototype (5 pcs), low volume (50–500), production (500+)?

Quote turnaround: 48 hours for standard configurations; 3–5 business days for custom engineering.

Frequently Asked Questions

What is the difference between multi-core coaxial and Bundled Micro Coaxial Cable ?

The terms are interchangeable. "Multi-core" emphasizes high core count; "bundled micro coaxial" emphasizes the construction method. Both describe multiple individually shielded coaxial elements in one harness — the key technical characteristic being per-channel shielding. Industry usage varies by region: "multi-core coaxial" is more common in European NDT specifications; "bundled micro coaxial" is more common in Asian medical device manufacturing.

Can multi-core coaxial cable be phase-matched?

Yes. TDR-measure every cable, sort into ±0.25% bins, assemble and verify to ±1.0% or ±0.5%. Per-channel TDR certificate shipped with every phase-matched assembly. Phase matching is our core manufacturing capability — over 70% of our multi-core coaxial production is phase-matched.

What core counts are available?

4 cores to 512 cores. Standard for ultrasound: 128, 192, 256, 288. For NDT PAUT: 32, 64, 128. For endoscopy: 6, 8, 16, 32, 64. Custom counts at same MOQ — 5 assemblies prototype, 50 production.

What is the maximum frequency for multi-core coaxial cable?

Individual elements are rated to 6+ GHz. In bundled configuration, practical bandwidth depends on length and crosstalk budget. At 2 m length: > 3 GHz usable. At 5 m: > 1 GHz. For ultrasound (1–60 MHz) and NDT (0.5–25 MHz), bandwidth is never the limiting factor.

How does cost scale with core count?

Roughly linear for cable material. Assembly labor increases sub-linearly (256 cores costs approximately 1.7× of 128 cores, not 2×). Phase matching adds 15–25%. Connector termination is the largest variable — I-PEX ZIF termination for 256 channels adds significant labor versus bare-end bundles.

Need a multi-core coaxial cable assembly? Share core count, AWG, and application — quote within 48 hours.

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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.