What Are Twin Axial High Speed IO Cables - Miracle Electronics

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Copper twin axial raw wires have been developed
for more than five decades now, and are yet
being used in all kinds of diverse applications.
Today, these wires, after receiving much trust
and authority, are being used for several new
generation I/O interface standard and custom wire
assemblies. They are being used for both
internal and external assembly applications
within enterprise infrastructures, high
performing computer systems, commercial data
centers, and many other consumer applications.
However, these wires are yet quite expensive,
which poses a challenge for manufacturers to
produce budget-friendly ones, and for users to
pay a little extra for the extra performance
that they expect. But, in spite of the price,
these wires are yet used preferably in expensive
test equipment for 56 Gbps per lane circuits,
and for handling 100W power closely adjacent to
sensitive high-speed digital signaling per
interface specifications like USB 3.1 and the
latest power over Ethernet IEEE-802.3
specifications. Here are some tips on how a wire
assembly manufacturer can overcome these
challenges, by considering these guidelines as
part of the component engineering process.
Although it is easy to cut down costs while
designing a quality wire harness , but it could
be a little challenging in the case of twin axial
high speed I/O cables.
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• Having relationships with strong suppliers can
  address any and all material, quality, process,
  performance, and testing variations details.
• The raw wire from one reel should be used for I/O
  link assemblies because of slight, but critical
  performance variations from one reel to another.
  Thats because it depends on how tight the wire
  is reeled up, and the difficulty of maintaining
  structure symmetry. Generally, each reel of the
  raw wire is individually measured,
  characterized, and documented for use by the wire
  assembly supplier, and the traceability by the
  OEM or end user.
• The wire conductor gauge size versus electrical
  signaling reach should be
• carefully considered. The dielectric material
  properties that will achieve needed signaling
  performance ranges must be looked out for. This
  may include evaluating solid, air, and foam
  types. Also, the process variation tolerance and
  control of bubble size, symmetry, density, and
  distribution must be looked at.
• Pure copper conductor elements with very low
  oxygen content, when used, can optimize
  conductivity. The conductor silver-plating
  smoothness and purity must be considered,
  enabling best electrical skin effect relative to
  signal
• launch path, insertion loss, jitter, and
  reflection loss.
• Twin axial differential pair elements need to be
  layered within the bundle for optimized element
  fan out and prepping, relative to the termination
  zone. The
• pair shields need to hold tight geometries when
  processing and wire termination prepping, and
  also for wire bundle shields and fillers. In
  addition, the bundle diameters and bend radius
  need to be designed relative to the wire
  routing.
• Wire termination to contacts or PCB pads must be
  watchfully done for both signal and ground
  conductors and wire bundle shield termination.
  The best technologies must be used for every
  process right from wire termination shaping and
  smoothness to welding or soldering.
• All in all, you need to find a manufacturer that
  is up to the mark and perfect at producing
  nothing but only the best for your application.
  And, Miracle Electronics is one such name that
  tops the list of the most reliable wire harness
  manufacturers from India, where you can get high
  performing wire harnesses, especially customized
  to your needs.

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