Configuring cable assemblies, a step-by-step guide

Configuring RF (radio frequency) or MW (microwave) cable assemblies can be a complex and time-consuming task. Even the smallest decisions around impedance, frequency range, temperature rating or jacket material can have a big impact on system performance, reliability and compliance.

That’s where online cable assembly configurators can make things much easier. Rather than looking for specific information within datasheets or moving back and forth between countless emails, these tools can guide you through the process step by step. Helping you define exactly what your application needs, correctly and efficiently.

We’ve put together a helpful guide, that can walk through how to use our cable assembly configurators, how to understand the filters we’ve set up to help you, and why this approach is increasingly valuable in modern RF and MW design.

Selecting from thousands of part numbers can be overwhelming to the most competent engineers. Once you’re clear of your application, you need to consider specific filters that can help narrow these down. For instance, selecting a range of either 50 or 75 Ohms of impedance can remove incompatible cables, as can selecting a specific frequency range (GHz) ensure signal integrity at your operating frequency. Use temperature ratings for specific environments (aerospace, defense, rail or industrial)

Specific cable filters such as temperature range and applications can then be selected, depending on your mechanical requirements.

You’ll know the filters are working for you, when you see a list of a thousand+ cables reduce to specific configurations to meet your needs.

At this stage, you’re typically choosing between trade offs such as smaller diameter vs lower loss, higher temperature rating vs flexibility, standard constructions vs specialised high performance designs.

Take a comparative approach between key parameters that the configurator makes across products. This reduces the risk of selecting a cable that technically “fits” but isn’t optimal for long term performance.

Length definition might sound trivial, but it’s one of the most common sources of misunderstanding in RF assemblies.

Configurators typically specify:

• The assembly length definition ( for example, reference - reference)
• Exact units (mm or inches)

By forcing a clear definition at this stage, you can avoid ambiguity and ensure the finished assembly matches your expectations. This is especially important for when you might require repeat orders or are configurating for multi site projects.

Once the cable is defined, the next step is choosing connectors for each end of the assembly. Compatibility and the correct termination options are of course, the most important factor here as well as consistency between your left and right sides.

Avoid manually checking mating interfaces and cable compatibility. Our HUBER+SUHNER configurators restrict your choices to only those combinations that work in practice.