Ultrasound cable assembly stands for the most difficult processing in micro coax assembly
Among our ultra thin coax assembly business,Ultrasound cable assembly is one of our main advantages. As We are a specialized ultrasound cable assembly manufacturer,our engineers in charge of ultrasound probe cable assembly has more than 15 years experience in precision medical cable assemblies built with micro coaxial wire. Our solutions are tailored for ultrasound probes, endoscope camera imaging, and other diagnostic equipment where high signal integrity and compact design are essential because of the limited space .
Video of whole progress of Ultrasound cable assembly
Watch Our Manufacturing Process
To many of us,it is unbelievable that a human hand and eye can assembly so thin coaxial up to 256 core and thin to 40-46AWG. In order to show you a complete processing in our workshop ,which is specially equiped for medical cable assembly with fine wire coax for ultrasound,we make this video
Ultra thin coax assembly need advance devices to assist,See how we produce high-precision ultrasound wire and cable assemblies, from CO₂/YAG laser cutting to CCD-monitored pulse welding and full electrical testing.
What Capabilities Should an Ultrasound Cable Assembly Manufacturer Have?
High-precision micro coax cable processing (36~46 AWG)
Processing single core micro coaxial cables at 36 to 46 AWG requires specialized wire stripping, crimping, soldering and termination tools,which can prevent damage to the ultra-thin inner conductor and insulation. Any mechanical stress, over-stripping, or conductor nicking can lead to signal degradation or long-term reliability failure. If you will spare time,single core ultra coax can be processed mamually,but When cores reach up to 256 cores,the difficulty increased multiple,Assistant devices is a must:
High-precision handling ensures:
• Consistent signal transmission with minimal attenuation
• Flexibility without breakage (especially at cable bend points)
• Reliable performance in tight spaces inside probes
Imported CO₂ and YAG laser systems for clean shield/braid cuts
Using imported laser systems like CO₂ (for outer jacket) and YAG (for metallic braid and foil) ensures:
• Precise, non-contact cutting that avoids mechanical damage
• Minimal heat-affected zones to protect underlying insulation
• Clean braid edges for easier grounding/welding and better shielding continuity
Without laser precision, traditional mechanical stripping can fray shields, cause braid shorts, or leave particles that risk insulation breakdown
Pulse welding for grounding tabs with CCD visual control
Pulse welding makes precise energy control during bonding of grounding tabs, so it will avoid overheating or weak/fake joints. With the CCD camera magnifying the visual and monitoring,there problems can be solved,and bring these benefits:
• Ensures consistent weld depth and placement
• Minimizes rework or invisible cold joints
• Guarantees stable low-resistance grounding paths
This is particularly critical for ultrasound systems where grounding must be perfect to avoid RF interference or ghost imaging.
Automated wire routing with high alignment accuracy
For ultrasound cable,the inner coax usually are divided into several groups based on the colors,each group,the wire are in the same color insulation,when there are 20-30 wires each group in one color,it is almost impossible to distinguish them and solder them correctly.especially when micro coax number reach 198 core or 204 core or 256 core
Automated routing systems solved this challenge and improve efficiency and accurancy:
• Reduce operator error during cable laying
• Maintain exact spacing and orientation of each micro coax
• Ensure repeatability from prototype to mass production
Poorly routed wires can lead to:
• Internal stress concentration → fatigue failure
• Inconsistent impedance across channels
• Trouble during overmolding or connector assembly
100% electrical testing: continuity, impedance, insulation resistance
This is basic requirement for wire harness not only in ultrasound cable assembly,when it comes to high precision devices and high value cables,it become more obvious
Because Complete electrical testings ensures:
• Continuity: No open or short circuits across signal lines (for most wire harness,they regard cable pass QA after when Conductivity testing pass)
• Impedance Matching: Essential for minimizing signal reflection in high-frequency probes(impedance is a basic features for Coaxial.As micro coax has thin insluation ,any pressure may influence its impedance much)
• Insulation Resistance: Prevents leakage between shield and signal wires, ensuring patient safety( detect if there is any damaged during the stripping)
Low-cost vendors often spot-check or test only continuity, but 100% testing (with proper jigs and simulation loads) guarantees every cable meets spec before delivery
Applications
- B-mode ultrasound probe assemblies
- Color Doppler ultrasound systems
- Surgical visualization / endoscopy
- Veterinary and portable ultrasound devices
what we offer
- As a dedicated ultrasound cable assembly manufacturer, we understand the unique challenges of medical device integration.
- Custom-tailored cable designs-from raw cable to cable assembly (includes High capacitance micro coax and foamed teflon low capacitance micro coax
- ISO-compliant quality control
- Low-MOQ prototypes & scalable mass production (Cable quantity low to 50 meters)
- Fast lead times and strong engineering support (3-4 weeks is our regular leadtime,2weeks with extra charge)
