One thing is sure when creating top-notch, UL-certified RF cable assemblies: attention to the smallest details matters. For over 25 years, Meridian Cable has been committed to quality manufacturing standards and to attending to the finest details. We’ve got some of the most brilliant minds in the industry on our in-house engineering team to help design, prototype, test, and manufacture custom RF cable assemblies for industries all over the globe. 

Our decades of experience and commitment to outstanding work in our field means that you get a cable assembly you can depend on. We build entirely custom RF cable solutions to the most exacting detail. We’ll cover everything you need to know to start your custom RF cable assembly project with our team.

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What is an RF Cable Assembly?

Also known as a coaxial cable, an RF cable is a standard cable used to transmit visual and audio signals. An RF cable is typically identified by its connectors which have a single pin in the center of the connector. This pin inserts into the dock while the surrounding connector encompasses the outside of the dock. This design allows RF cables to connect securely while blocking out potential interference. These powerful cables are used in any industry that utilizes visual or audio equipment so that they can be found in an array of outlets. 

In the days of cable television, RF cables were seen in nearly every home. Now, while not used as frequently for home televisions, RF cable assemblies are a significant component for countless applications.

The cable assemblies used in electronically noisy areas need to be protected from EMI. EMI can significantly impact the effectiveness of data transmission using cable assemblies. By interfering with the cable assemblies’ ability to transmit data effectively, EMI can be a severe issue for an unshielded cable assembly. While a cable's insulation and jacket helps protect the conductors from moisture, breaks, and kinks, they do not protect from any type of EMI.

Advantages of Custom RF Cable Assemblies

These capable cable assemblies have a lot to offer for radio, television, music industries, and more. Because of their simple-to-use design, RF cable assemblies are easy to install. This clever design also makes them easy to extend with a coaxial extender. Additionally, RF cable assemblies are known for their durability and longevity. Because they are often used with heavy sound or TV equipment, durability comes in handy. 

Another benefit of RF cable assemblies is they have excellent resistance to electromagnetic interference (EMI). When used in electronically noisy environments, the inner shielding helps block out interference that could damage or destroy the transmitted signal. EMI can be the death of data if a cable is not properly shielded. 

Lastly, when Meridan designs and builds your RF coaxial cable assemblies, you can rest easy knowing that expert engineers oversee every detail. Our design team completely customizes your cable solutions so you get a tailor-made product. Sure, you could get some off-the-shelf products from any electronic store that may do the bare minimum of the job. But then you run the risk of getting something that doesn’t quite fit your individual needs. At best, a one-size-fits-all solution will barely get the job done. At worst, a poorly manufactured cable could bring down your whole system. It is far better to know that your cable solution is made just for your equipment and that it is held to the highest manufacturing standards. 

Here at Meridian Cable, we stand behind every custom RF cable assembly we manufacture. Our commercial warranty guarantees that our products will be free of manufacturing and material defects. We believe in our products and strive to create the best quality for our customers. You can trust our expert team to design, prototype, test, and manufacture top-notch cable solutions for your business.

Building a Custom RF Cable Assembly

When we create custom cable assemblies, wire harnesses, or any of our other products, it’s important to start with the conductor. By working from the conductor out, our design team can build a precise cable to suit your unique needs. From the core to the outer jacket, you have options every step of the way to design the ideal RF cable solution for your business. 

When we say that we have our eyes on every step of the process, that’s exactly what we mean. We start by extruding the conductors from raw materials. This means we can closely monitor the process to ensure quality and accuracy. We’re proud to have and maintain our ISO 9001 certification, in addition to a host of other industry-recognized certifications for our near-fanatical commitment to quality. 

Each product we build undergoes a lengthy, labor-intensive process before it is ready to mass produce. We take quality seriously and thoroughly test each product to ensure that it is capable, holds up to industry standards, and performs excellently. When a custom RF cable assembly is ready for mass production, it has been repeatedly tested for durability, functionality, and quality. We do this to guarantee that our products are precisely what our clients require in a cable solution. 

Custom Conductor Size

Because the conductor is the critical component for transmitting a signal, it is important to ensure it will have the necessary capacity. The appropriate conductor size can make all the difference in custom RF cable assemblies. The intended use for the cable assembly and your equipment will determine what size conductor you need. In the initial design process, you will work with our in-house engineering team to help you get the ideal conductor size for your system. 

While we can create a wide range of conductor sizes, don’t let the specifics overwhelm you. Our team will help you determine precisely what you need for your audio or visual equipment. Typically, we offer conductor sizes ranging from 34 gauge to 12 gauge. Different sizes can be combined within an assembly to make the perfect connection. 

Insulation

Once the conductor is finalized, custom coaxial cable assemblies need a layer of insulation. Insulation in an RF cable serves to help protect the conductor from outer elements and hazards. Keeping the innermost layer covered is essential to ensure the successful operation of the cable assembly. If the conductor is compromised, kinked, or unprotected, it will perform poorly or potentially damage equipment. 

The insulation also serves a secondary purpose in holding the frequency within the cable. Acting as a barrier for the electronic pulses in the conductor, the insulation keeps the flow of electricity where it should be. This ensures proper function and safe operation. 

We offer several options for insulation material to best fit your equipment. While each material will perform a similar task, your equipment may require a specific material. You may also select a different insulation material to work better with your system or to improve durability. No matter what you need, we have you covered for all custom RF cable assembly applications. 

 

You can select insulation materials from any of the following:

  • PVC
  • PE
  • PP
  • Teflon
  • Natural rubber

Customizable Conductor Material

While typical RF cable conductors are made from copper, we can customize your conductors with rare metals to suit your equipment. Depending on your equipment, adding an alloy or mixed metal can boost the cable’s capacity and optimize performance. Not all sound or tech gear will require additional materials, but we can accommodate whatever you need.

Shielding

The all-important shielding is next to the final layer in custom RF cable assemblies. RF coaxial cables are known for their resistance to EMI and are an industry standard for this feature. The shield layer blocks EMI from messing with the conductor and scrambling the signal. In that sense, shielding is just what it sounds like. But proper shielding is more than mere defense. As the shield blocks out the EMI, it also grounds it to disperse it securely. This two-fold action is exactly the protection a conductor needs to operate successfully. 

In most designs, the shield layer for RF cable assemblies is thin strips of copper braided into a woven tube. This braided design effectively helps block EMI's danger while allowing the cable flexibility to be coiled into concentric loops. This will give you the protection and flexibility to move and connect your RF cables as your equipment requires. With the security shielding provided, your RF cable is intended to be durable and withstand harsh audio and visual work conditions.

Final Layer: Adding a Jacket

Once the previous steps have been completed, it’s time to add the jacket around the outside. The jacket is the outermost protection for an RF cable. It can be made from a range of materials and serves to hold everything together. This final step in the design process is what will protect the inner parts of the cable assembly from moisture, dirt, and debris. Depending on your equipment and environment, you can select a jacket material to optimize durability, flexibility, or longevity. 

Once the jacket is selected, your design for custom RF cable assemblies is complete. We will then move on to the prototyping and testing phases of production.

In most designs, the shield layer for RF cable assemblies is thin strips of copper braided into a woven tube. This braided design effectively helps block EMI's danger while allowing the cable flexibility to be coiled into concentric loops. This will give you the protection and flexibility to move and connect your RF cables as your equipment requires. With the security shielding provided, your RF cable is intended to be durable and withstand harsh audio and visual work conditions.

The Meridian Cable Promise

When you choose Meridian Cable for custom RF cable assemblies, you can relax knowing that our team is on top of it. We’ve been a leading provider of custom cable solutions for over 25 years and can handle any job you have for us. Contact our team to get a quote on your custom cable solution. 

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