Why miniature micro coaxial cable is changing wearable device design

Wearable devices have evolved dramatically from the basic step counter to full health monitors, AR/VR headsets, and smart clothing. But all this new technology requires smaller, lighter, more capable internal cables in greater quantities than ever before. Traditional ribbon cables and discrete wiring may face challenges in meeting these evolving demands. They take up too much space, interfere with other signals, and the reliability of signals passing through numerous discrete wires quickly become a problem. Enter the miniaturized micro coaxial cable—a technology that is enabling next-generation wearable device development. At Hotten, with the ability to develop over 300 new cable specifications annually and a 10,000 sq. ft. facility dedicated to precision engineering, we are at the forefront of this revolution, producing high-performance micro coaxial cable assemblies for AR/VR cables, wearable devices, drone wire harnesses, and more.

Ultra-Compact Size Enables Slimmer Device Profiles

The primary advantage of a miniature micro coaxial cable is its size. Although traditional coaxial cables are excellent at signal transmission, their sheer size is a problem, especially when space is at a premium in wearable devices. Micro coaxial cable, on the other hand, can achieve an outer diameter (OD) as low as 0.1 mm to 0.3 mm, while still delivering extremely high quality signals.

With ultra-small cable sizes, industrial designers can produce leaner, lighter and more comfortable wearable devices. AR/VR head mounted displays can achieve better weight distribution. Smartwatches can fit more functionality into smaller casings, and medical wearables becomes much less obtrusive. Hotten's miniature micro coaxial cables—constructed with a very fine center conductor, an extremely thin fluoropolymer insulation layer, and a low profile braided shield—allow manufacturers to integrate higher functionality into increasingly smaller enclosures.

Superior Signal Integrity in Noisy Wearable Environments

Wearables are basically an electrically noisy environment. Everything from processors and wireless radios (Bluetooth, Wi-Fi, 5G) to power management circuits, display drivers create significant electromagnetic interference that can affect extremely sensitive signals. High-resolution camera feeds and high-speed display interface are very sensitive, but so are medical devices that take precise readings of biometrics.

A micro coaxial cable inherently rejects much unwanted noise. The shielding around the center conductor isolates the signal from external interference and other wires, while also containing the magnetic field so it does not affect other signals. High bandwidth video signals, which are carried over AR/VR cables, or a gimbal camera wire harness that is transferring raw video feeds, need the superior shielding and accuracy of a micro coaxial cable. Hotten's micro coaxial cables provide an ample and tight fitting braided shield around the signal wires, allowing the signal to transmit without being disturbed.

Enhanced Flexibility for Dynamic Wearable Applications

A wearable must move with the body. A smart clothing fabric will stretch with every step the wearer takes, and an AR/VR cable harness will be constantly twisted and bent as the wearer looks left and right. Even the best round wires must be precisely positioned to avoid pulling in one direction, which hampers movement and prevents the cables from bending freely. The flat flexible cables have great maneuverability, but the strands cannot take the repeated mechanical stress required by a wearable.

A micro coaxial cable provides exceptional flexibility since its center conductor will be a very fine stranded wire and will be isolated by an ultra thin jacket. This allows them to be routed cleanly around corners and bent in unusual directions. Because multiple micro coaxial cables can be combined to form round or flat wire harnesses, this approach is highly efficient at delivering signals to their destinations without compromising device wearability. Robotics and drone wire harnesses both heavily rely on a high degree of flexibility in a small, protected harness.

Weight Reduction for Comfort and Performance

It may not sound like it, but any ounce can and will significantly impact on a wearable. Heavier devices cause user fatigue. Medical wearables, in particular, must not be too heavy, or user compliance will suffer. Even on a consumer AR/VR headset, excessive weight on the back of the head can contribute to uncomfortable and painful sessions. With traditional shielded wires taking up a significant chunk of weight due to their physical size, reducing it can be one of the biggest benefits.

With a micro coaxial cable, manufacturers can achieve significant weight savings by implementing fine gage micro coaxial cable instead of multiple standard shielded cables or discrete wiring. For drone wire harnesses this can lead to increased flight time and payload capacity. Hotten's average daily production volume of 144 million meters includes over 14 million meters of micro coaxial cable, which contributes to these reductions in the wearable and consumer electronics market.

High-Density Interconnects for Advanced Functionality

The number of sensors and devices packed into even the simplest of wearable electronics today is increasingly complex. High resolution cameras, bio-metric sensors, eye-tracking, and haptic feedback systems, among others, all have a direct interface in the device and require interconnects. All these signals need to travel in and out of a very small enclosure without excessive size increase.

Micro coaxial cable makes high-density interconnects feasible by being able to fit many signals in an extremely small cross-section. A simple wire harness that includes dozens of high-speed, individually shielded signals along with power and control wires may still only take up a few cubic centimeters in space. Hotten's USB4 and LVDS cable harnesses often employ a micro coaxial construction in order to achieve necessary channel densities in the next generation wearable. We take great strides with our engineering department to develop custom configurations.

Durability for Real-World Wearable Use

Wearable devices often face the toughest and least desirable of conditions. Sweating, liquids, changing temperatures, direct sun and repeated flexing will all degrade performance on even the best electronics. A wire harness must be durable enough to stand up to all these conditions while maintaining a constant connection and ensuring signal fidelity.

Jacketing on a micro coaxial cable will often be made from very durable TPU (thermoplastic polyurethane), silicone, or abrasion-resistant nylon, depending on what conditions the wearable may face. Shield terminations are engineered to prevent strain and to minimize damage. Hotten's attention to detail coupled with over 40 manufacturing units helps to ensure we make every micro coaxial wire harness ready to meet industry standards and stand up to real-world use.

Conclusion

Miniature micro coaxial cable is revolutionary for wearable device development, making smaller form-factors, improved signal integrity, increased flexibility, reduced weight, higher interconnect densities and enhanced durability possible. Hotten leverages this revolutionary technology by building a vast supply chain to accommodate a multitude of industry needs in various consumer electronics. From AR/VR cables and drone wire harnesses to medical wearable devices, Hotten continues to develop and produce custom solutions to take your next wearable product to the next level.