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30-34 AWG Twin Axial Product Line

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At Epic Polymer Solutions, we have the expertise to provide high reliability, high performance cable cores within industry-leading turnaround times. We manufactured the 32 AWG GBit twinaxial primaries shown here as components for an RF parallel pair shielded cable for a next-generation mainframe server mass data storage application.

Specifications called for .0250″ O.D. polypropylene coated 3201 silver and tin plated copper wire, so we developed tightly controlled and supervised melt extrusion process in order to achieve accuracy of ±0.00025″. We also designed specialized pressure tooling that created a smooth finish and eliminated tip clogs from the tin plated wire. In process inspections using precision laser gauging equipment monitored the incoming wire diameter and coated wire diameter, as well as its ovality and concentricity, while integrated Fast Fourier Transform software allowed us to measure structural return loss. We also performed various other quality assurance processes including capacitance testing, strip force measurement, and pinhole detection.

SPC reports validated that we achieved concentricity greater than 95% and ovality less than 0.0003” on the coated wires, which would allow a nearly perfect signal to pass through. This product meets Infiniband, Fibrechannel, QSFP, and QSFP+ standards. By having the right production and test equipment, we are able to manage high throughput of up to 12 MM/week on an ongoing basis.

If you would like more information about this project, or would like to discuss how we can innovate a solution to meet your custom requirements, contact us today.

30-34 AWG Twin Axial Product Line Highlights

Product Name: 32 AWG GBit Twinax Primaries

Product Description: Polypropylene insulated copper wire for an RF parallel pair shielded cable Used for next generation Mainframe server mass data storage systems

Capabilities Applied/Processes:

  •  Primary: Melt extruded wire coating

  •  Secondary: Fast Fourier Transform

Equipment Used to Manufacture Part: Extruder, Incoming wire laser OD gauge, Coated wire OD gauge, Ultra short electrode length capacitance gauge, Closed loop wire tension control system, Integrated Fast Fourier Transform (FFT)/Structural Return Loss (SRL) Software, Flaw detection, Spark tester

Overall Part Dimensions: .0250” OD coated 3201 Silver and Tin Plated Copper

Tightest Tolerances: +/- 0.00025

Materials Used: Polypropylene

In process testing/inspection performed: Natural

In process testing/inspection performed: Incoming wire diameter, Coated wire diameter, Ovality, Capacitance, Concentricity, Pinhole detection, Structural return loss (SRL), Strip Force

Industry for Use: Computer mainframe mass data storage

Volume: Up to 12 MM/Week

Delivery/Turnaround Time: 3-4 Weeks

Delivery Location: Worldwide

Standards Met: Infiniband, Fibrechannel, QSFP, QSFP+