Medical Cable Solutions

At High Performance Medical Solutions (HPMS) we pride ourselves on offering some of the most advanced and specialized cable capabilities in the market. 

Our team of experts is highly skilled in producing small, complex cables using a variety of materials, including discrete wire, micro-coaxial, twisted pairs, and twinaxials. No matter what your specific requirements may be, we can work with you to design and manufacture a custom solution that meets your product specific needs.

Our range of standard sizes is unparalleled, with options as small a fine wire drawn down to 58AWG to create 50AWG conductor (7/58, 0.10 mm diameter). This level of precision and attention to detail is essential for highly specialized and complex cables.

Fine Wire for Surgical, Ultrasound, Catheter, and Endoscopy

Speak with an Expert
To Discuss Your Application Needs

Wire & Cable Capabilities

Our range of standard sizes is unparalleled, with options as small a fine wire drawn down to 58AWG to create 50AWG conductor (7/58, 0.10 mm diameter).
This level of precision and attention to detail is essential for highly specialized and complex cables.
 
  • High performance conductor allows
  • Impedence or capacitance controlled
  • Flex and electrocial testing capability
  • Hybrid-cabling for multi-purpose applications
  • Research and development for next generaiton needs
  • Standard and custom designs available 

Discrete Fine Wire Medical Cable Leader

Proterial specializes in building complex fine wire bundles that are traditionally found in ultrasound imaging environments for medical probe cables in both medical and non-medical applications where precision and performance are paramount. This expertise can be expanded upon to other applications such as endoscopes, catheters, and animal probes.

Cable Cross Section Compared to a Penny

Micro-Coaxial Cable

Micro-coaxial cable is used in a wide array of precision medical products and cabling applications, where limited space, high reliability, high-sensitivity and outstanding signal, capacitance and impedance characteristics are important.

Ideal for ultrasound probes, catheters, endoscopy, oximetry systems, sensors, robotics and industrial automation and inspection. We offer a full range of standard sizes from 32 to 50 AWG using high-strength silver-plated or tinned-copper alloys that are rated to +200°C. Our micro-coaxial cable is a market leader due in part to our proprietary high-strength alloys with outstanding low-loss characteristics. 

Features and Benefits:

  • Micro diameter and light weight
  • Excellent heat resistance and electrical characteristics with fluorocarbon polymer insulation
  • Excellent mechanical strength and flexible performance with copper alloy conductor.
Copper alloy wire wrapped around an 80 micron human hair.
Proterial copper alloy wire wrapped around an 80 micron human hair.
High Capacitance Micro-Coaxial

We offer a broad selection of copper alloy wire with precision wire gauges ranging from 36 AWG to 50 AWG. These superfine, high strength, highly conductive 7 strand constructions are useful for small diameter flexible cables. We offer standard 50 & 60 Ohm impedence products.

Please call if alternate constructions are required.

High Capacitance Micro-Coaxial Cable - Jacket, Shield, Insulation, Inner Conductor

High Capacitance Micro-Coaxial Cable

Coaxial Product NumberAWG StrandingMaterialConductor DCR@20⁰C Ω/kft / (Ω/km)Insulation MaterialShield MaterialJacket MaterialJacket DiameterCapacitance pF/ft (pF/m)Impedance @10MHz (Ω)
5361-11036 (7/44) (7/0.05 mm)Tinned Copper 479 (1,569)PFA = PerfluoroalkoxyTinned CopperPFA = Perfluoroalkoxy0.021 (0.54)33.6 (110)50
5381-11038 (7/46) (7/0.04 mm)Tinned Copper Alloy1,007 (3,300)PFA = PerfluoroalkoxyTinned CopperPolyester Tape or PFA0.017 (0.44)33.6 (110)50
5382-11038 (7/46) (7/0.04 mm)HiFC®610 (2,000)PFA = PerfluoroalkoxyTinned CopperPolyester Tape or PFA0.017 (0.44)33.6 (110)50
5401-11040 (7/48) (7/0.031 mm)Tinned Copper Alloy1,525 (5,000)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape or PFA0.013 (0.32)33.6 (110)50
5402-11040 (7/48) (7/0.031 mm)HiFC®975 (3,200)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape or PFA0.013 (0.32)33.6 (110)50
5411-11041 (7/49) (7/0.028 mm)Silver Plated Copper Alloy1,525 (5,000)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape or PFA0.012 (0.31)33.6 (110)50
5421-110*42 (7/50) (7/0.025 mm)Silver Plated Copper Alloy2,227 (7,300)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape or PFA0.011 (0.29)33.6 (110)50
5431-11043 (7/51) (7/0.023 mm)Silver Plated Copper Alloy2,288 (7,500)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape or PFA0.011 (0.27)33.6 (110)50
5441-11044 (7/52) (7/0.02 mm)Silver Plated Copper Alloy3,203 (10,500)PFA = PerfluoroalkoxySilver Plated Copper AlloyPolyester Tape or PFA0.010 (0.24)33.6 (110)50
5451-11045 (7/53) (7/0.018 mm)Silver Plated Copper Alloy3,752 (12,300)PFA = PerfluoroalkoxySilver Plated Copper AlloyPolyester Tape or PFA0.009 (0.22)33.6 (110)50
5461-11046 (7/54) (7/0.016 mm)Silver Plated Copper Alloy4,728 (15,500)PFA = PerfluoroalkoxySilver Plated Copper AlloyPFA = Perfluoroalkoxy0.008 (0.20)35.1 (115)50
5481-11048 (7/56) (7/0.012 mm)Silver Plated Copper Alloy7,010 (23,000)PFA = PerfluoroalkoxySilver Plated Copper AlloyPFA = Perfluoroalkoxy0.007 (0.17)36.6 (120)50
5501-12550 (7/58) (7/0.01 mm)Silver Plated Copper Alloy11,430 (37,500)PFA = PerfluoroalkoxySilver Plated Copper AlloyPFA = Perfluoroalkoxy0.006 (0.15)38.1 (125)50
5401-09040 (7/48) (7/0.031 mm)Silver Plated Copper Alloy1,525 (5,000)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape0.015 (0.37)27.5 (90)60
5411-09041 (7/49) (7/0.028 mm)Silver Plated Copper Alloy1,525 (5,000)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape0.014 (0.35)27.5 (90)60
5421-09042 (7/50) (7/0.025 mm)Silver Plated Copper Alloy2,227 (7,300)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape0.013 (0.32)27.5 (90)60
5431-09043 (7/51) (7/0.023 mm)Silver Plated Copper Alloy2,288 (7,500)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape0.012 (0.3)27.5 (90)60
5441-09044 (7/52) (7/0.02 mm)Silver Plated Copper Alloy3,203 (10,500)PFA = PerfluoroalkoxyTinned Copper AlloyPolyester Tape0.011 (0.27)27.5 (90)60
Low Capacitance Micro-Coaxial

Proterial’s advanced foam PFA extrusion process delivers low capacitance cable with reliable performance. We utilize a polyester tape skin over the foam to deliver the dielectric withstand voltage required by the medical industry. 38 AWG to 48 AWG wire sizes are available. These are 70, 75, and 85 Ohm impedance cables.

Low Capacitance Micro-CoaxialLow Capacitance Micro-Coaxial

Low Capacitance Micro Coaxial Cable

Coaxial Product NumberInner Conductor- AWG (Stranding)Inner Conductor – MaterialConductor DCR@20°C Ω/kft (Ω/km)Insulation MaterialShield MaterialJacket MaterialJacket – Diameter – Inch (mm)Capacitance pF/ft
(pF/m)
Impedance @10Mhz (Ω)
5381-06038 (7/46) (7/0.04 mm)Silver Plated Copper Alloy1,007
(3,300)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.021
(0.54)
18.3
(60)
75
5401-06040 (7/48) (7/0.03 mm)Silver Plated Copper Alloy1,525
(5,000)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.016
(0.41)
18.3
(60)
75
5411-06041 (7/49) (7/0.028 mm)Silver Plated Copper Alloy1,525
(5,000)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.014
(0.36)
18.3
(60)
75
5421-06042 (7/50) (7/0.025 mm)Silver Plated Copper Alloy2,227
(7,300)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.013
(0.34)
18.3
(60)
75
5431-06043 (7/51) (7/0.023 mm)Silver Plated Copper Alloy2,288
(7,500)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.012
(0.31)
18.3
(60)
75
5441-06044 (7/52) (7/0.02 mm)Silver Plated Copper Alloy3,203
(10,500)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.011
(0.28)
18.3
(60)
75
5461-06046 (7/54) (7/0.016 mm)Silver Plated Copper Alloy4,728
(15,550)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.01
(0.25)
18.3
(60)
75
5481-070*48 (7/56) (7/0.013 mm)Silver Plated Copper Alloy7,010
(23,000)
PFA with Airspace Aperture
(+Polyester tape skin)
Silver Plated Copper AlloyPolyester Tape0.008
(0.21)
21.4
(70)
70
5401-05040 (7/48) (7/0.03 mm)Silver Plated Copper Alloy1,525
(5,000)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.019
(0.47)
15.3
(50)
85
5411-05041 (7/48) (7/0.03 mm)Silver Plated Copper Alloy1,525
(5,000)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.016
(0.4)
15.3
(50)
85
5421-05042 (7/50) (7/50) (7/0.025 mm)Silver Plated Copper Alloy2,227
(7,300)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.016
(0.41)
15.3
(50)
85
5431-05043 (7/51) (7/0.023 mm)Silver Plated Copper Alloy2,288
(7,500)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.014
(0.35)
15.3
(50)
85
5441-05044 (7/52) (7/0.02 mm)Silver Plated Copper Alloy3,203
(10,500)
Cellular PFA
(+Polyester tape skin)
Tinned Copper AlloyPolyester Tape0.013
(0.32)
15.3
(50)
85
Solid Conductor Micro-Coaxial Cable

Proterial solid conductor constructions combine all the attributes of the stranded wire coaxials while offering a slightly smaller diameter with improved current carrying capacity, and lower loss.

Features and Benefits: 

Micro-Coaxial Performance

The chart below is a useful tool for understanding the behavior of a single coaxial (with 7 strand conductors) in relation to size, group bundling, frequency and flex life.Micro-Coaxial Performance

Micro-Coaxial Performance Chart

Item48 AWG (7/56)
(7/0.012 mm)
(120 pF/m)
46 AWG (7/54)
(7/0.016 mm)
(115 pF/m)
48 AWG (7/56)
(7/0.012 mm)
(70 pF/m)
46 AWG (7/54)
(7/0.016 mm)
(60 pF/m)
Diameter of micro-coaxial.006 in
(0.165 mm)
.008 in
(0.195 mm)
.0085 in
(0.215 mm)
.010 in
(0.250 mm)
Cable Diameter
(128 micro-coaxial)
.122 in
(3.1 mm)
.138 in
(3.5 mm)
.150 in
(3.8 mm)
.169 in
(4.3 mm)
Characteristic Impedance
(at 10 MHz)
50 Ω50 Ω70 Ω75 Ω
Capacitance
(at 1 kHz)
120 pF/n115 pF/n70 pF/n60 pF/n
Inner Conductor Resistance21.5 Ω/m14.5 Ω/m21.5 Ω/m14.5 Ω/m
Attenuation
(at 10 MHz)
2.1 dB/m1.45 dB/m1.3 dB/m0.85 dB/m
Attenuation
(at 50 MHz)
2.9 dB/m2.35 dB/m1.8 dB/m1.25 dB/m
+/- 90 degrees bend test
(Radius = 2mm)
Over 500k cyclesOver 500k cyclesOver 500k cyclesOver 500k cycles

Single Lead Wire

In addition to Micro-coaxial cable, Proterial offers high performance single lead wire which is at the heart of our Micro-coaxial line. Providing extremely thin wall PFA and our standard alloy materials, our lead wire offers the same exceptional characteristics that customers have come to expect.

Stranded Construction Table

Stranded Construction Table

Single Lead Wire – Stranded Construction

Physical Construction Description:
Insulated hook-up wire, consisting of 1 conductor, unshielded and unjacketed made with PFA.
Single Lead Wire Product NumberInner Conductor
AWG (Stranding)
Inner Conductor
Material
Conductor DCR@20°C
Ω/kft
(Ω/km)
Insulation
Material
Diameter
Inch
(mm)
ME-PFA 1X36 AWG36
(7/44)
(7/0.05mm)
Tinned Annealed Copper479
(1,572)
PFA.01
(0.26)
ME-PFA 1X38 AWG38
(7/46)
(7/0.04mm)
Tinned Copper Alloy1,006
(3,300)
PFA.008
(0.21)
ME-PFA 1X40 AWG40
(7/46)
(7/0.031mm)
Tinned Copper Alloy1,524
(5,000)
PFA.006
(0.16)
ME-PFA 1X41 AWG41
(7/49)
(7/0.028 mm)
Silver Plated Copper Alloy1,524
(5,000)
PFA.006
(0.155)
ME-PFA 1X42 AWG42
(7/50)
(7/0.025 mm)
Silver Plated Copper Alloy2,286
(7,500)
PFA.005
(0.135)
ME-PFA 1X43 AWG43
(7/51)
(7/0.023 mm)
Silver Plated Copper Alloy2,286
(7,500)
PFA.005
(0.13)
ME-PFA 1X44 AWG44
(7/52)
(7/0.02 mm)
Silver Plated Copper Alloy3,200
(10,500)
PFA.005
(0.12)
ME-PFA 1X45 AWG45
(7/53)
(7/0.018 mm)
Silver Plated Copper Alloy3,749
(12,300)
PFA.004
(0.011)
ME-PFA 1X46 AWG46
(7/54)
(7/0.016 mm)
Silver Plated Copper Alloy4,724
(15,500)
PFA.004
(0.095)
ME-PFA 1X48 AWG48
(7/56)
(7/0.012 mm)
Silver Plated Copper Alloy7,315
(24,000)
PFA.003
(0.085)
ME-PFA 1X50 AWG50
(7/58)
(7/0.01 mm)
Silver Plated Copper Alloy11,430
(37,500)
PFA.003
(0.075)
Solid Construction Table

Stranded Construction Table

Single Lead Wire – Solid Construction

Single Lead Wire Product NumberInner Conductor- AWG (Stranding)Inner Conductor – MaterialConductor DCR@20°C
Ω/kft
(Ω/km)
Insulation – MaterialDiameter – Inch(mm)
ME-PFA 1X40AWG(1/0.080)40
(1/40)
(1/0.080 mm)
Silver Plated Copper Alloy1,373
(4,500)
PFA.0055
(0.14)
ME-PFA 1X42AWG(1/0.064)42
(1/42)
(1/0.064 mm)
Silver Plated Copper Alloy2,135
(7,000)
PFA.005
(0.124)
ME-PFA 1X44AWG(1/0.051)44
(1/44)
(1/0.051 mm)
Silver Plated Copper Alloy3,355
(11,000)
PFA.004
(0.101)
ME-PFA 1X46AWG(1/0.04)46
(1/46)
(1/0.040 mm)
Silver Plated Copper Alloy5,399
(17,000)
PFA.003
(0.080)
ME-PFA 1X48AWG(1/0.03)48
(1/48)
(1/0.030 mm)
Silver Plated Copper Alloy9,608
(31,500)
PFA.003
(0.070)
ME-PFA 1X50AWG(1/0.025)50
(1/50)
(1/0.025 mm)
Silver Plated Copper Alloy13,878
(45,500)
PFA.00025
(0.065)
NOTE: Custom colors and adjustments in wall thickness available upon request.

Hybrid Bundle Cables

Our bundles can include many different styles of cables in addition to micro-coaxial cable. Proterial offers various tubing for air or fluidics, specialty optical fiber for data and power transport, or just basic data and power copper wiring. We custom design each cable for whatever evolving and demanding need occurs. Hybrid bundling of a multi-function cable is also available.

Features & Benefits:

Ultrasound Cable

A number of micro-coaxials are bundled for ultrasound probe cable. Typical design specifications should include the style of coax, the number of coax, the shield configuration, flexibility requirements, type of sheath and sheath color. Custom designs are also available upon request.

Ultrasound Cable Ultrasound Cable

Fine Wire for Surgical, Catheter & Endoscopy

The applications for medical probe cables, typically used in ultrasound diagnostic apparatus, can be expanded to other medical equipment such as endoscopes, catheters, and animal probes. Proterial Cable offers customized cable to meet specific needs depending on the application or equipment.

Our high strength micro-coaxial cable with ultra-thin medical grade jacketing is the optimal solution for advanced catheter applications.

Features and Benefits: 

  • Various lineup of micro-coaxial and twinaxial cable : ~50AWG (Min)
  • Ultra-thin fluorine resin PFA jacket : ~15μm (Min) available
  • Ultra-accurate extrusion & cabling technology
  • Custom designs available

Medical Twisted Pairs & Twinaxial Cables

Standard twisted pairs can be used for differential signal lines (putting equal but opposite voltage on each of the wires). This ensures that noise effects are significantly reduced. Typically twisted pairs reach their limits around ~2-4 Gbps while twinaxials can perform well at higher transmission rates. Twisted pairs may have better flex characteristics over twinaxial designs.

Twinaxial constructions have the pairs laid parallel to each other. This approach allows for very high bandwidth applications greater than that of common twisted pairs. They result in lower attentuation due to a shorter travel distance, better impedance characteristics and better control of skew within the pair. Typically twisted pairs reach their limits around ~2-4 Gbps while twinaxials can perform well at higher transmission rates. Twinax signals are especially good at 5 Gbps+ up to and as high as 25 Gbps / channel currently.

Features and Benefits
  • Twisted quad cable available : ~48AWG (Min)
  • Solid conductor wire available ; Pair ~48AWG (Min), Quad ~46AWG (Min)
  • Custom designs available. See cable examples below. Call for design support.

 

Cable Specific Examples

Medical Twisted Pairs and Twin axial Cables

StructureInner Conductor
AWG
(Stnading)
Material
Inner Conductor
DCR@20°C
Ω/kft
(Ω/km)
insulationsPair
Diameter
Inch (mm)
Shield
Material
Jacket
Material
Jacket
Diameter
Inch(mm)
Capacitance
pF/ft
(pF/m)
Impedance
@10Mhz
(Ω)
Cable Example 1Shielded Twinax w/o Jacket40
(7/48)
16,404
(5,000)
PFA008 x .016
(0.203 x 0.406)
6 Ends 46 AWG Hard Tin Copper48 pF/m100 +/- 5
Cable Example 2Shielded Twinax w/Jacket40
(7/48)
16,404
(5,000)
PFA.008 x .016
(0.203 x 0.406)
6 Ends 46 AWG Hard Tin CopperPET TAPE.016 x .024
(0.406 x 0.610)
48 pF/m100 +/- 5
Cable Example 3unshielded Twisted Pair
w/o Jacket
48
(7/56)
(7/0.013 mm)

Silver Plated Copper Alloy
24,000
(7,230)
PFA.007
(0.178)
TBDTBD
Cable Example 4unshielded Twisted Pair
w/Jacket
48
(7/56)
(7/0.013 mm)

Silver Plated Copper Alloy
24,000
(7,230)
PFA.007
(0.178)
PFA.009
(0.229)
TBDTBD
Cable Example 5Shielded Twisted Pair48
(7/56)
(7/0.013 mm)

Silver Plated Copper Alloy
24,000
(7,230)
PFA.007
(0.178)
Silver Plated Copper AlloyPFA.011
(0.279)
TBDTBD
Cable Example 6Unshielded Twisted Pair
w/o Jacket
50
(7/58)
(7/0.01 mm)

Silver Plated Copper Alloy
40,500
(12,370)
PFA.0055
(0.14)
TBDTBD
Cable Example 7Unshielded Twisted Pair
w/Jacket
50
(7/58)
(7/0.01 mm)

Silver Plated Copper Alloy
40,500
(12,370)
PFA.0055
(0.14)
PFA.008
(0.203)
TBDTBD
Cable Example 8Shielded Twisted Pair50
(7/58)
(7/0.01 mm)

Silver Plated Copper Alloy
40,500
(12,370)
PFA.0055
(0.14)
Silver Plated Copper AlloyPFA.009
(0.229)
TBDTBD

Methods for Reducing Thermal Resistance

Thermal Management of Medical Cables and Devices is becoming increasingly challenging and critical to the reliability and usability of advanced surgical, imaging and implantable devices. As the trend for lighter, smaller and more operable cables continues so will the trend for finer wire with increased coaxial counts. This will drive the ongoing need for improved cable and device thermal management. When designing a cable, the shield design can have a significant impact on thermal resistance. Secondly, an improved shield can be further improved with a proper thermal connection. Contact Proterial for additional support to maximize your designs’ performance.

Methods for Reducing Thermal Resistance Table

Thermal Resistance Reduction

Methods for Reducing Thermal Resistance Table
Speak with a Medical Cable Solutions Specialist to get started!
Speak with a Medical Cable Solutions Specialist to get started!