Communication Systems | Cable USA High Performance Cables
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Communication Systems

Rugged Cable Securing Voice, Data, and Video Transmission

Cable USA is a leading ITAR Registered manufacturer of rugged military cable and coil cords designed to perform in the most severe combat conditions. Our tactical-assured products are widely used on noise-canceling handsets and headsets, various types of microphones, radios, auxiliary systems and push-to-talk (PTT) systems. In addition to voice transmission, our communication cables have evolved to include internet protocol (IP) based components that offer systems a level of situational awareness never before seen on the battlefield. Since the first Gulf War our communications cable and coil cords have been deployed and our multiple tours of duty keep us on the front lines of battlefield communication.

Ground Communication Systems Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Communication Systems

Ground Communication Systems

Cable USA has developed a family of rugged military cable and coil cords that offer a complete capability across a wide spectrum of requirements that support Communication Systems and Next-Generation Digital Communication Systems. We manufacture radio remote control, radio power, backbone / highway, loudspeaker, alarm, bailout and bailout extension cables. We can incorporate power, data, and audio into single fully rugged military cable or cord with our hybrid cabling and shielding technologies. Our products are found on numerous platforms ranging from light vehicles, heavily armored, medical and mobile command centers around the world.

  • Supports Push-To-Talk (PTT), Voice-Operated Transmitter (VOX), Live Mic, Active Noise Reduction (ANR) and Emergency override
  • Hybrid PWR + Data Constructions to support C4ISR
  • Monaural and Binaural Headset Support
  • Enhanced Flex-Life
  • Ruggedized against EMI / RFI
  • Nuclear, Biological, and Chemical (NBC) Compliant
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
  • Ruggedized CAN-BUS, RS-232, RS-422, USB, HDMI, and Ethernet constructions available
Pilot and Flight Deck Communications Systems Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Communication Systems

Pilot & Flight Deck Communication Systems

Cable USA has developed a family of rugged military cable and coil cords that offer a complete capability across a wide spectrum of requirements that support Rotary and Fixed Wing Communication Systems and Next-Generation Digital Communication Systems. Our communication cables or coil cords seamlessly integrate into Rotary and Fixed Wing helmet systems providing state-of-the art, secure audio communications without sacrificing protection.

  • Supports Push-To-Talk (PTT), Voice-Operated Transmitter (VOX), Live Mic, Active Noise Reduction (ANR) and Emergency override
  • Hybrid PWR + Data Constructions to support C4ISR
  • Monaural and Binaural Headset Support
  • Enhanced Flex-Life
  • Ruggedized against EMI / RFI
  • Nuclear, Biological, and Chemical (NBC) Compliant
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
  • Ruggedized CAN-BUS, RS-232, RS-422, USB, HDMI, and Ethernet constructions available

Marine Communication Systems

On the water reliable communication is a must. We provide the water-resistant rugged military cable and coil cords to support intercom system specially designed for crew intercommunication and radio access in combatant, patrol and rescue craft. Our products are rugged, light-weight, marine-grade and water resistant.

  • Supports Push-To-Talk (PTT), Voice-Operated Transmitter (VOX), Live Mic, Active Noise Reduction (ANR) and Emergency override
  • Hybrid PWR + Data Constructions to support C4ISR
  • Monaural and Binaural Headset Support
  • Enhanced Flex-Life
  • Water Resistant
  • Ruggedized against EMI / RFI
  • Nuclear, Biological, and Chemical (NBC) Compliant
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
  • Ruggedized CAN-BUS, RS-232, RS-422, USB, HDMI, and Ethernet constructions available
Tactical Handheld Radio Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Communication Systems

Tactical Handheld Radio Cable

The modern tactical radio offers much more than simple voice transmission. The radio can include embedded applications, networking, GPS positioning, video and the ability to interoperate with numerous platforms. Tactical radios can function like miniature computers and the cables that support them needs to be as versatile. Cable USA’s tactical-assured designs and manufacturing capabilities provide the military and homeland security divisions with an ever-expanding line of rugged military cable solutions to support:

  • Push-To-Talk (PTT), Voice-Operated Transmitter (VOX), Live Mic, Active Noise Reduction(ANR) and Emergency override
  • Enhanced Flex-Life
  • Secure High-Speed Data Transmission
  • Ruggedized against EMI / RFI
  • Nuclear, Biological, and Chemical (NBC) Compliant
  • SWAP-C focused constructions
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow

Typical Applications:

  • Wideband Tactical Radio
  • UHF Soldier Radio
  • High Frequency Radio
  • Wideband Networking Radio
  • Handheld Multiband Radio
  • Multiband Tactical Handheld Radio
  • High Frequency Manpack Radio
  • Tactical Network Access Hub
  • Tactical Video Processor
  • Broadband Global Area Network (BGAN)
  • High Frequency Tactical Radio
  • International Handheld Radio
  • Multiband Networking Radio (MBNR)
  • Mobile Computing Platform
  • Secure Personal Radio
  • Situational Awareness Video Receiver (SAVR)
  • VHF Combat Net Radio (CNR)
  • High Capacity Line-of-Sight (HCLOS) Radio
  • Multi-Channel Manpack Radio
  • Mid-Tier Networking Vehicular Radio
  • Wideband Team Radio
  • Soldier Personal Radio
  • Multiband Combat Net Radio (CNR)

Typical Cable Design:

  • PPP Data Cable
  • Remote Control Cable
  • Synchronous Data Cable
  • KDU Cable and KDU Extension Cable
  • 24V AC/DC Battery Eliminator
  • Ruggedized Ethernet
  • Micro Miniature Cable
  • Micro Patch
  • Micro USB
  • Extended Length USB
  • RS-232
  • HDMI
  • CAN-BUS
  • Micro CAN-BUS
  • Digital Retransmission
  • RS-232 + Ethernet
  • Break-out/Extension
  • GPS + Remote Control + Ethernet + RS-232
  • Dual Wire, Ethernet + USB + RS-232
  • Remote Control Console
  • RS-232 + LAN + Remote Control
  • Voice + RS-232 + Ethernet
  • Ethernet + RS-232 + Remote Control + Voice
  • Triple Wire w/Voice + Remote Control + RS-232 + Ethernet
  • Vehicle Mount RS-232 + Remote Control + Ethernet
  • RS-232 + Ethernet + Remote Control + RS-232
  • Data + Console
  • RS-232 + Console
  • Voice + Data
  • Data + Remote Control
  • HPW Cable
  • GPS Data Cable (PLGR and DAGR)
  • USB Programming Cable
  • Battery Extension Cable
  • Dual Battery PWR
  • Dual Radio Battery Eliminator
  • Battery Eliminator
C4SIR and WIN-T Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Communication Systems

C4ISR and WIN-T

C4ISR is a military term that stands for Command, Control, Communications, Computers, Intelligence, Surveillance and Reconnaissance. The technology allows war fighters to have real-time access to lifesaving intelligence. Cable USA can fuse high-speed data components into legacy designs or redefine the specifications with innovative voice + power + data hybrids to give your next-generation programs the C4ISR edge. Cable USA provides the critical connection needed to significantly increase situational awareness in support of WIN-T. Our rugged military cable products give platforms the ability to capture and process larger volumes of information and securely transmit voice, data, video and images faster and more efficiently throughout the combat zone.

Typical Applications:

  • Ruggedized Tablets
  • Video Receivers
  • Command Centers
  • Digital Intercommunication Systems
  • Soldier-Worn Electronics
  • On-The-Move Networking Systems
  • UAV
  • Global Broadcast Service
  • Secure Satellite Communications
  • Line-of-Sight (LOS) communications
  • Beyond-LOS (BLOS) communications
Coil and Retractable Communication Cord Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Communication Systems

Coil and Retractable Communication Cord

We manufacture rugged military coil cords and retractile cables that support power, data and audio transmission individually or all together as a composite design.  These Military-grade cords are resistant to harsh environments and extreme temperatures all of while maintaining maximum flex-life.

Product Attributes:

  • Constructions Available up to 200°C and 1000V
  • Wide Range of gauge sizes
  • Monaural and Bi-naural Headset Support
  • Designs can support high speed data transmission
  • Coil Body lengths available from 1” to 72”
  • Enhanced Flex-life
  • Tangent or Axial Tails
  • Proprietary coiling procedure effectively eliminates tangle ability
  • Available with EMI / RFI protection
  • Nuclear, Biological, and Chemical (NBC) Compliant
  • Excellent “Snap-back” characteristics
  • RoHS Compliant
  • Custom Designs

Typical Applications:

  • Handset and Headset
  • Loudspeaker
  • Audio
  • Telescoping Mast
  • Portable Power
  • Lighting
  • Radar
  • Robots
Micro and Miniature Coax Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Communication Systems

Micro and Miniature Coax

We offer an extensive line of micro and miniature sized coax cable to support the discrete requirements of equipment. Our products are used in Night Vision and Weapon Optics, Internal Flat Panel Displays, Mounted Camera’s, Test and Measurement Sensors, Internal Wiring on electronic equipment and radio frequency.

  • Small Diameter and Lightweight
  • High Speed Transmission
  • Excellent Heat Resistance and Electrical Properties
  • Excellent Mechanical Strength
  • Enhanced Flex-Life
  • Precision controlled tolerances
  • Available in sizes from #26 to 40
  • Available with Solid, Semi-Solid, and Cellular Insulations

RG Style Coax Equivalents

Equivalents

We manufacture equals to other manufacturer’s part numbers and equivalents to unnecessary agency approved cables.  In most cases, we can offer both better pricing and lower minimum buy quantities.

For example:

We offer two varieties of (non-QPL) equivalents to the standard RG/U and M17 cables.

  • Cost effective cables that are electrically and dimensionally equivalent
  • Electrically equivalent that dimensionally fit your specific application

There are other options available.  Please use our “Build Your Own” form or call your local sales representative to submit your request.

MIL-W-22759/16

MIL-W-22759/16 wires have extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Stranded Tinned Copper
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Standard Wall

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/16 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-22759/17

MIL-W-22759/17 wires have extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Silver Plated Copper Alloy
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Standard Wall – High Strength Conductor

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/17 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-22759/18

MIL-W-22759/18 wires have thin wall extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Stranded Tinned Copper
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Thin Wall

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/18 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-22759/19

MIL-W-22759/19 wires have thin wall extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Silver Plated Copper Alloy
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Thin Wall – High Strength Conductor

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/19 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-16878/1 Type B

MIL-W-16878/1 (Type B) PVC hook up wire is suitable for internal wiring of meters, panels and electrical or electronic equipment. It is also popular for harness applications in the military and aerospace industries. It is flame and chemical resistant.

Passes UL VW-1 Flame Test

RoHS Compliant

MIL-W-16878/1 Type B Wire (M16878/1) Construction:

  • Conductor: Stranded Tinned Copper
  • Insulation: Polyvinylchloride (PVC)
  • Nominal Wall Insulation Thickness: 0.010”

MIL-W-16878/1 Type B Wire (M16878/1) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 600 Volts

MIL-W-16878/2 Type C

MIL-W-16878/2 (Type C) PVC hook up wire is suitable for internal wiring of meters, panels and electrical or electronic equipment. It is also popular for harness applications in the military and aerospace industries. It is flame and chemical resistant.

Passes UL VW-1 Flame Test

RoHS Compliant

MIL-W-16878/2 Type C Wire (M16878/2) Construction:

  • Conductor: Stranded Tinned Copper
  • Insulation: Polyvinylchloride (PVC)
  • Nominal Wall Insulation Thickness: 0.016″

MIL-W-16878/2 Type C Wire (M16878/2) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 1000 Volts

MIL-W-16878/3 Type D

MIL-W-16878/3 (Type D) PVC hook up wire is suitable for internal wiring of meters, panels and electrical or electronic equipment. It is also popular for harness applications in the military and aerospace industries. It is flame and chemical resistant.

Passes UL VW-1 Flame Test

RoHS Compliant

MIL-W-16878/3 Type D Wire (M16878/3) Construction:

  • Conductor: Stranded Tinned Copper
  • Insulation: Polyvinylchloride (PVC)
  • Nominal Wall Insulation Thickness:
    • 14-26 AWG: 0.031″
    • 2-12   AWG: 0.037″

MIL-W-16878/3 Type D Wire (M16878/3) Ratings:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 3000 Volts

MIL-W-16878/7 Type F

Low Smoke, Zero Halogen Silicone – 600 V, 200°C

M16878/7 Wire Description:

M16878/7 Wire is designed to be flame retardant and meet Navy regulations on smoke, toxicity, and acid gas. Applications include those requiring high flexibility, durability, and high temperature applications.

M16878/7 Wire Ratings and Approvals:

  • Mil Spec: M16878/7
  • Temperature Rating: 150 °C
  • Voltage Rating: 600V

NM16878/7 Wire Construction:

  • Conductor: Soft annealed silver plated copper
  • Insulation: Extruded silicone

MIL-W-16878/8 Type FF

1000 V, 200°C

M16878/8 Wire Description:

MIL-W-16878/8 has low smoke characteristics. Type FF is designed to be flame retardant and meet Navy regulations on smoke, toxicity, and acid gas. Applications include those requiring high flexibility, durability, and high temperature applications.

M16878/8 Wire Ratings and Approvals:

  • Mil Spec: MIL-W-16878/8
  • Temperature Rating: 200 °C
  • Voltage Rating: 1000V

M16878/8 Wire Construction:

  • Conductor: Silver plated copper
  • Insulation: Extruded silicone

MIL-W-16878/10

Construction:

  • Conductor: Tinned Copper
  • Insulation: Extruded Polyethylene

Ratings:

  • Max. Temperature: 75°C
  • Max. Voltage: 600 volts

MIL-W-16878/11 | NEMA HP4 Type K

Passes UL VW-1 Flame Test

MIL-W-16878/11 Wire (NEMA HP4 Type K) Description:

  • Conductor: Tinned Copper (Silver-Coated Copper also available)
  • Insulation: Extruded FEP, .010 Nominal Wall Thickness

MIL-W-16878/11 Wire (NEMA HP4 Type K) Characteristics:

  • Temperature Range: -55°C to +150°C
  • Voltage Rating: 600 Volts

MIL-W-16878/12 | NEMA HP4 Type KK

Passes UL VW-1 Flame Test

M16878/12 Wire (NEMA HP4 Type KK) Description:

  • Conductor: Tinned Copper (Silver-Coated Copper also available)
  • Insulation: Extruded FEP

M16878/12 Wire (NEMA HP4 Type KK) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 1000 Volts

MIL-W-16878/13 | NEMA HP4 Type KT

Passes UL VW-1 Flame Test

MIL-W-16878/13 Wire (NEMA HP4 Type KT) Description:

  • Conductor: Tinned Copper (Silver-Coated Copper also available)
  • Insulation: Extruded FEP, .006 Nominal Wall Thickness

MIL-W-16878/13 Wire (NEMA HP4 Type KT) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 250 volts

MIL-W-16878/29 Type F

MIL-W-16878/29 Wire (M16878/29 Wire) Construction:

  • Conductor: Stranded Tinned Copper, Color Coded
  • Insulation: Extruded Silicone Rubber

MIL-W-16878/29 Wire (M16878/29 Wire) Characteristics:

  • Temperature Range: 150°C
  • Voltage Rating: 600 volts

MIL-W-16878/30 Type FF

MIL-W-16878/30 MIL Spec Wire Description:

  • Conductor: Stranded Tinned Copper, Color Coded
  • Insulation: Extruded Silicone Rubber

MIL-W-16878/30 MIL Spec Wire Characteristics:

  • Temperature Range: 150°C
  • Voltage Rating: 1,000 volts

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