Semi-Rigid RF & Microwave Cable Assemblies

Published on 12/16/2025 • Updated on 1/4/2026

Semi-Rigid RF & Microwave Cable Assemblies

In the demanding realms of aerospace, defense, and satellite communications, where space constraints meet ultra-high performance needs, semi-rigid RF cable assemblies emerge as the gold standard for reliable signal integrity.  Coaxial Cable type RG-401, RG-402, and RG-405.

Manufacturers with decades of expertise, like those at specialized RF facilities, produce these assemblies in-house using fully equipped tool rooms for custom jigs and fixtures. This approach slashes costs and lead times while leveraging advanced setups including programmable thermo-cycling chambers, cable forming machines, clean rooms, and vector network analyzer (VNA) test equipment to deliver comprehensively tested products.

Semi-rigid cables strike a unique balance: pliable enough for custom bending into precise shapes, yet rigid enough to maintain form under vibration and thermal stress. Skilled operators use specialized tooling to form these cables without damaging the delicate walls, ensuring optimal electrical performance.

Versatile Cable Variations

  • Sizes and Jackets: From 0.020” to 0.500” diameters, with copper-jacketed options (silver or tin plated), aluminum jackets (0.047” to 0.325”), and stainless steel jackets (0.034”, 0.047”, 0.086”, 0.141”).

  • Conductor Options: Stainless outer with stainless or copper center; copper lines in stainless steel jackets for enhanced durability.

  • Dielectrics: Low-loss types, phase-stable non-PTFE options, and non-50Ω variants across sizes.

  • Performance Grades: High-frequency assemblies up to 26 GHz, space-qualified, phase- or amplitude-matched sets.

Every assembly undergoes 100% testing with detailed plots for return loss, insertion loss, and phase stability.

Critical Applications

These assemblies shine in space, defense, aerospace, satellite systems, and precision instrumentation. In satellites, they route signals through tight compartments without compromising microwave performance. Defense radar and avionics benefit from their vibration resistance and thermal stability, while test benches rely on matched sets for accurate measurements.

With in-house customization from prototypes to high-volume runs, semi-rigid microwave assemblies empower engineers to conquer the toughest RF challenges, blending form, function, and reliability in compact designs.


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