The Manufacturing Process Behind Micro Coax Cable Assemblies

Apr 03, 2026

The micro coax cable assembly is the invisible superhero in the world of AR/VR, industrial drones, and healthcare-related technologies, which are rapidly changing. These small but powerful parts have the task of providing high-frequency signals at the lowest possible losses another requirement of modern electronics that cannot be compromised.

We have been working to find the ropes in this complex art at Hotten Electronic, which started in 2018, and is situated in eastern China. As an R&D-based core company with an ultra-fine coaxial cable technology, we are developing more than 300 new cable specifications every year out of our 10,000-square-meter workshop. However, what does turn the raw materials into a high performance cable assembly? It is a union of progressed machinery, high quality control and customized engineering expertise.

This is a backstage view of the way micro coax cable assemblies are made.

What Are the Main Manufacturing Steps for Micro Coax Cable Assemblies?

Direct Answer

Micro coax cable assemblies are manufactured through a controlled sequence of fine-wire processing, insulation, coaxial construction, shielding, jacketing, precision cutting and stripping, termination, and final inspection.

The important point is that manufacturing a micro coax assembly is not simply a smaller version of conventional coaxial cable production. As the cable diameter and conductor size decrease, dimensional control, material consistency, coaxial geometry, shielding, termination accuracy, and inspection become increasingly important.

A typical manufacturing flow is:

Fine-wire preparation → Insulation → Coaxial construction → Shielding → Jacketing → Cutting & Stripping → Termination → Electrical & Mechanical Testing

Manufacturing stage	Main engineering control	Result
Fine-wire preparation	Conductor size and consistency	Stable electrical and mechanical foundation
Insulation	Dielectric thickness and uniformity	Controlled electrical characteristics
Coaxial construction	Concentricity and geometry	Consistent transmission behavior
Shielding	Coverage and structure	EMI control and signal isolation
Jacketing	Thickness, material and flexibility	Mechanical and environmental protection
Cutting & Stripping	Controlled preparation	Protects conductor and shield
Termination	Alignment and contact quality	Reliable finished connection
Final Testing	Electrical, dimensional and mechanical checks	Finished assembly verification

For OEM projects requiring fine-wire and micro coaxial assemblies, see HOTTEN's Micro Coaxial Cable and Micro Coaxial Cable Assembly solutions.

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Step 1: Material Selection & Wire Drawing

The process starts with raw materials which are normally copper or copper alloy conductors. Because micro coax cables commonly have conductor diameters on the order of microns, fineness is of primary importance. In Hotten, it begins by drawing wire and in this process, raw wire is pulled through a series of dies, so as to obtain the required thickness. Any error of 0.001mm can influence consistency of impedance. This step establishes the background to signal integrity, a bottom-line concern in our medical and industrial uses.

Step 2: Extrusion & Insulation

When the conductor is prepared, then it has to be insulated to avoid leakage of signals. That is where such materials as FEP, PFA, or ETFE are involved. The insulation layer is deposited with high precision extruders with concentricity tolerances which are within or beyond industry standards. In the case of ultra-fine coaxial cables, the homogeneity of this dielectric coating is very important- capacitance and signal velocity directly depend on it.

Step 3: Braiding & Shielding

Electromagnetic interference (EMC) is an unavoidable enemy in the era of 5G and the delivery of video in high quality. Multi-layer shielding is used in our micro coax assemblies, frequently in foil wraps coupled with braided metal meshes. It involves special braiding machineries that can work with filament with the fineness of human hair. More than 40 production machines operate 24/7 at Hotten to guarantee dense and flexible shielding coverage a balance needed when it comes to dynamic uses such as drone gimbals or surgical robots.

Step 4: Jacketing

The outer jacket protects the cable. Our choices of materials to use are polyurethane or PVC depending on the application. In the case of medical endoscopes, the jacket should be sterilizable and biocompatible. In the case of industrial drones, it should be able to withstand abrasion and high temperatures. This layer is deposited without damaging the fine internal topography by calibration of our extrusion lines. This is not extrusion as such; it is micro-engineering.

Step 5: Cutting & Stripping

One of the most sensitive stages now follows. The micro coax cables cannot be cut by use of normal blades unlike conventional wiring. The danger of scratching center conductor or interrupting the shield is excessive. We employ laser based cutting and resistance based stripping systems that cut away insulation layers with surgical precision. This is usually what makes the difference between a working connection to one that causes signal reflection.

Step 6: Termination & Connector Attachment

And a cable assembly is as good as its connections. We have technicians and automated machines collaborating to install micro-miniature connectors, typically I-PEX, Hirose or even custom designs. This is a process of soldering or laser welding that is done under a magnification. In the case of medical ultrasound probes, this should be done in such a way that the signal loss is zero. In the case of AR/VR headsets, it should be able to guarantee high-speed data transfer without delays.

Step 7: 100% Functional Testing

Quality is not a gateway in Hotten; it is a culture. Each of the assemblies is thoroughly tested. This includes:

Continuity & Hi-Pot testing in order to confirm that it is electrically safe.

Impedance / VSWR test to check signal transmission efficiency.

Pull force test and flex life test to imitate the real life mechanical tests.

The visual examination with automated optical devices.

Having a production capacity of over 144 million meters per annum, this degree of scrutiny necessitates standard work processes and a no-tolerance attitude to zero defects.

Manufacturing Stage	Main Process	Key Quality Focus
1. Wire Drawing	Reduce conductor diameter	Dimensional consistency
2. Insulation	Precision extrusion	Dielectric consistency and concentricity
3. Shielding	Foil and/or braided shielding	EMI protection and coverage
4. Jacketing	Outer protective layer	Flexibility and environmental resistance
5. Cutting & Stripping	Precision preparation	Avoid conductor and shield damage
6. Termination	Connector attachment	Electrical and mechanical reliability
7. Final Testing	Electrical and mechanical inspection	Functional and quality verification

What Are the Main Manufacturing Steps for Micro Coax Cable Assemblies?

The Human Element: R&D as the Backbone

Our process cannot be without mentioning the engineers who make it happen. Our R&D team is fully collaborating with clients at the design-to-manufacturing stage with more than 300 new cable specifications provided annually. It can be a custom impedance number of a military grade drone or a miniaturized bend radius of a neurovascular catheter, but it is our ability to prototype quickly and with great scale that makes a good idea a stable industrial or medical system.

Engineering Selection and OEM Manufacturing Considerations

1. Fine-Wire Manufacturing Sets the Foundation for the Final Cable

The manufacturing process begins with the conductor.

For ultra-fine electronic wire, the production target is not simply a smaller conductor. The conductor must maintain consistent:

Diameter
Material properties
Surface condition
Electrical resistance
Mechanical characteristics

If an OEM requires very small conductors, then conductor dimensional consistency should be controlled before the coaxial cable is built, because variation introduced at the wire stage can carry through to later insulation, shielding, and termination processes.

For applications requiring ultra-fine conductors, see HOTTEN's Thin Electronic Wire capabilities.

2. Insulation Controls More Than Electrical Isolation

The insulation layer separates the conductor from the surrounding conductive structure, but in micro coaxial cable it also contributes to the overall electrical geometry.

Important parameters include:

Insulation parameter	Why it matters
Material	Influences dielectric behavior and environmental performance
Thickness	Affects cable geometry and electrical characteristics
Uniformity	Helps maintain consistent performance along the cable
Concentricity	Supports stable coaxial geometry
Surface quality	Supports reliable downstream processing

If the cable requires controlled electrical characteristics, then insulation thickness and geometry should be treated as manufacturing parameters, because variation in the dielectric structure can affect capacitance and impedance.

3. Coaxial Geometry Must Remain Consistent Through Production

A micro coaxial cable depends on the relative position of the center conductor, dielectric, and shield.

The desired structure is:

center conductor → dielectric → shield

The more compact the cable becomes, the more important consistent geometry becomes.

If the center conductor or dielectric shifts within the coaxial structure, then electrical characteristics can vary along the cable, because the physical relationship between the conductive elements has changed.

This is one reason micro coaxial manufacturing requires coordinated process control rather than relying only on final product inspection.

4. Shielding Must Balance Electrical and Mechanical Requirements

Shielding helps control electromagnetic interference and unwanted signal coupling, but shielding construction also affects the mechanical properties of the cable.

Possible trade-offs include:

more shielding → greater protection

but potentially:

more shielding → larger OD / greater stiffness / more difficult termination

If the cable is used in a dynamic application such as a medical probe, UAV gimbal, or robotic system, then shielding should be selected together with flexibility requirements, because the electrical benefit has to remain compatible with the cable's mechanical movement.

For RF applications, see HOTTEN's RF Coaxial Cable Assembly.

5. Jacketing Is Part of the Cable's Functional Design

The outer jacket protects the internal cable structure, but it also influences:

Flexibility
Abrasion resistance
Cable OD
Surface characteristics
Chemical resistance
Routing behavior
Environmental durability

If the cable is used in a medical environment, then jacket material should be evaluated against the actual cleaning, disinfection, temperature, and other application conditions, because general material descriptions do not replace application-specific validation.

For medical applications, see Medical Cable Assembly.

6. Cutting and Stripping Require Controlled Cable Preparation

After the cable is manufactured, it must be prepared for termination.

The objective is to expose the required conductive structures without damaging:

Center conductors
Insulation
Shielding
Adjacent signal paths

If the cable uses fine conductors or miniature coaxial structures, then the stripping process should be matched to the cable construction, because excessive stripping force or inaccurate preparation can damage the electrical structure before connector assembly begins.

The required preparation method should therefore be defined together with the connector and termination design.

7. Termination Converts the Cable Into a Finished Assembly

The final cable assembly is only as reliable as its termination.

Depending on the customer's design, the termination may include:

Micro coaxial connector termination
Fine-wire termination
FPC connection
PCB connection
Soldering
Crimping
Shield termination
Overmolding
Strain relief

If the assembly uses a miniature connector, then cable preparation, conductor alignment, shield handling, and connector positioning must be controlled together, because a small termination error can affect both electrical continuity and mechanical reliability.

HOTTEN can integrate customer-specified connectors, FPCs, PCB interfaces, housings, and other components into the finished assembly according to the customer's drawing, BOM, part number, or sample.

8. The Finished Assembly Should Be Tested, Not Just the Raw Cable

A raw cable can meet its specification while the finished assembly still has a termination or connector problem.

Depending on the application, finished-product validation may include:

Test / Inspection	Purpose
Continuity	Verify all electrical paths
Resistance	Check conductor and contact condition
Insulation resistance	Verify electrical isolation where applicable
Hi-Pot	Evaluate dielectric withstand where applicable
Capacitance	Verify electrical loading
Impedance	Verify controlled transmission characteristics where required
Insertion loss	Evaluate high-frequency attenuation
Pull test	Verify termination mechanical strength
Flex test	Evaluate repeated movement
Dimensional inspection	Confirm finished assembly dimensions
Visual inspection	Identify assembly defects

If the cable is being qualified for a high-speed, RF, ultrasound, or other sensitive application, then testing should be defined around the finished assembly, because the complete signal path includes both the cable and its terminations.

9. OEM Manufacturing Should Begin With Controlled Engineering Information

For custom micro coaxial cable assemblies, the manufacturing process becomes more predictable when the supplier receives complete engineering information.

Useful inputs include:

OEM input	Examples
Cable specification	AWG, construction, OD
Electrical requirements	Impedance, capacitance, frequency, attenuation
Cable length	Finished length and tolerance
Connector	Manufacturer, series, PN
Pinout	Contact assignment
Shielding	Required structure
Mechanical	Bend radius, routing, exit direction
FPC / PCB	Drawing and interface requirements
Housing	Dimensions and assembly information
Testing	Electrical / mechanical requirements
Quantity	Prototype, pilot, annual volume

If the connector or interface is already fixed, then provide the exact PN and drawing, because termination and cable preparation depend on the actual connector geometry.

10. Prototype and Mass Production Require Different Process Controls

Micro coaxial manufacturing should be designed around a controlled transition:

Engineering Sample → Prototype → Pilot Production → Mass Production

At each stage, the focus changes.

Stage	Main focus
Engineering sample	Feasibility and construction
Prototype	Electrical and mechanical validation
Pilot	Process repeatability
Mass production	Production consistency and inspection

If the design changes after prototype validation, then the revised cable structure, connector configuration, or process parameters should be documented before pilot production, because the production assembly should remain consistent with the approved engineering configuration.

11. Supplier Capability Should Cover Fine Wire Through Finished Assembly

For OEM procurement, the supplier's capability can be evaluated as a complete process rather than by one manufacturing step.

A useful manufacturing chain is:

Fine electronic wire → Micro coaxial cable → Precision preparation → Connector / FPC / PCB termination → Finished cable assembly → Testing

If the customer is buying a finished cable assembly rather than raw cable, then the supplier should be able to control the key stages from fine-wire production through final assembly, because quality problems can otherwise move between different suppliers and become harder to trace.

HOTTEN's production focus is fine electronic wire and micro coaxial cable, while customer-specified connectors, FPCs, PCB boards, housings, and related components can be integrated into the finished assembly according to the required engineering design.

12. Manufacturing Requirements Should Be Matched to the Application

Different applications require different priorities.

Application	Manufacturing focus
Ultrasound	Fine conductors, low capacitance, density, flexibility, termination
Endoscope	Small OD, compact termination, bending performance
Camera / Vision	High-speed signal integrity, miniature interface
UAV	Lightweight construction, flexibility, vibration resistance
Robotics	Repeated motion, routing and mechanical durability
RF systems	Impedance, shielding, attenuation and connector transition
Compact electronics	Miniaturization, density and assembly integration

If the application is highly specialized, then manufacturing requirements should be derived from the actual device conditions, because the same micro coaxial construction is not automatically suitable for every application.

See HOTTEN's Medical Devices, UAV & Robotics, AI & Smart Electronics, and High Frequency & RF Systems solutions.

13. A Practical OEM Manufacturing Checklist

Before approving a custom micro coaxial cable assembly, OEM engineers and buyers can confirm:

Checkpoint	Key question
Fine wire	Is the required conductor size available?
Insulation	Are material and dimensional requirements defined?
Cable geometry	Is the coaxial structure controlled?
Shielding	Is the required shielding structure defined?
Jacket	Does it match the application environment?
Termination	Can the specified connector / interface be assembled?
Mechanical	Are bend, routing and strain-relief requirements defined?
Testing	Are finished-assembly tests specified?
Documentation	Are drawing and BOM revisions controlled?
Production	Can the design move from prototype to volume?

A reliable micro coaxial cable assembly is therefore the result of controlled fine-wire manufacturing, precise cable construction, accurate termination, and application-specific testing rather than one individual production step.

For OEM projects requiring custom micro coaxial structures and finished assemblies, see Micro Coaxial Cable Assembly.

Conclusion: From Our Workshop to the World

In Hotten Electronic we do not think of micro coax cable assemblies as system components, but as essential drivers of innovation. Whether it is high-frequency signals being fed through the interior of an MRI machine or providing crystal-clear video to a VR headset, thousands of hours of engineering perfection goes with them.

On our road to becoming one of the best global suppliers, the same motto discussed, quality and safety will not be discussed; it is our manufacturing DNA.

When you want to find a partner that can produce precision cable assemblies that are specific to your needs, whether it be a prototype or a mass production, then we should begin a discussion. Since at Hotten there is a connection in every way.

FAQ

1. How are micro coax cable assemblies manufactured?
Micro coax cable assemblies are typically manufactured through several stages, including conductor preparation, wire drawing, insulation extrusion, shielding, jacketing, cutting and stripping, connector termination, and final electrical and mechanical testing.

2. What materials are commonly used in micro coaxial cables?
Common materials include copper or copper-alloy conductors, FEP, PFA or ETFE insulation, metallic shielding materials, and application-specific jacket materials.

3. Why is manufacturing precision important for micro coax cable assemblies?
Small dimensional variations can affect characteristic impedance, capacitance, signal transmission and mechanical performance. Precise control of conductor, insulation and shielding dimensions is therefore important for high-frequency applications.

4. How are micro coax cable assemblies tested?
Depending on the application, testing may include continuity, Hi-Pot, impedance, VSWR, pull-force, flex-life and visual inspection.

5. Can micro coax cable assemblies be customized?
Yes. Customization may include conductor size, cable diameter, impedance, insulation material, shielding structure, connector type, cable length and termination configuration.

6. Can HOTTEN manufacture prototypes as well as production quantities?
Yes. HOTTEN supports customized cable development from engineering samples and prototypes through production-scale manufacturing.