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Soldier-Worn Systems

Enhanced Flex-Life, Smaller Package – Same Results

A soldier is the most significant weapon to any arsenal. A dismounted soldier, equipped with a situational awareness system, has real-time information that allows for faster, more accurate decision making.  Cable USA provides the rugged military cable and cords that offer a reduced footprint, decreased combat load and secure on-the-move connections in complete support of WIN-T.  Our cables come standard with enhanced flex-life and tensile strength based on years of flex and pull testing research and development.  Our designs, materials and manufacturing practices prove superior based on our experience from numerous field evaluations.

  • Diameter Reduction
  • Data+Video+Audio Designs
  • Light Weight
  • Excellent Crush & Cut-Through Resistance
  • Micro Data Transmission
  • EMI / RFI Protection
  • Enhanced Flex-Life
  • Enhanced Tensile Strength
  • Coil Cord Constructions
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
Ruggedized Light Weight USB Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Soldier-Worn Systems

Ruggedized Light Weight USB

USB is a very popular protocol on many soldier-worn systems. Using off-the-shelf USB is dangerous to both your design and the soldier because combat environments can include impacts or excessive pull force that would damage or destroy the sensitive construction of the standard cables. Our rugged military cables feature an external TPE crush resistant jacket over high performance insulations, conductors and bonded strength members. USB designs can be ordered as 2.0, 3.0 and OTG. We offer a variety of power wire sizes to meet your requirements.

  • Variety of Sizes for Data Transmission Line
  • Variety of Sizes for Power Transmission Line
  • Ruggedized against EMI / RFI
  • Available as USB 2.0 or 3.0
  • Available with OTG Sense line
  • Crush and Cut Resistant TPE Jacket
  • Enhanced Flex-Life
  • Bonded Strength Members
  • Multi-USB cables or Hybrid with other data type
  • Coil Cord Designs Available
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
Weight Reduced Coil and Retractile Cord Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Soldier-Worn Systems

Weight Reduced Coil and Retractile Cord

We manufacture custom coil cords and retractile cables that support power, data and audio transmission individually or all together as a composite design.  These rugged military 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
  • Designs can support high speed data transmission
  • Coil Body lengths available from 1” to 72”
  • Monaural and Binaural Headset Support
  • Enhanced Flex-life
  • Tangent or Axial Tails
  • Proprietary coiling procedure effectively eliminates tangle ability
  • Available with EMI / RFI protection
  • Excellent “Snap-back” characteristics
  • RoHS Compliant
  • Custom Designs

Typical Applications:

  • Handset and Headset
  • Tactical Tablet
  • Body-worn Display
  • Telescoping Mast
  • Portable Power
  • Lighting
  • Radar
  • Robots

Ruggedized HDMI

Cable USA offers rugged military grade HDMI 1.3b or 1.4. Our cables are rated up to category 5 and reliably transmit a 1080p signal. Our cable is designed to support rugged tablets, laptops, computers and tactical displays.

  • Ruggedized against EMI / RFI
  • Enhanced Flex-Life
  • Bonded Strength Members
  • Crush and Cut Resistant TPE Jackets
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
Ruggedized Ethernet Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Soldier-Worn Systems

Ruggedized Ethernet

Cable USA manufacturers rugged military cable compliant to CAT 5, 5e and 6 standards.  Our Micro Patch line is designed around the SWAP-C initiative and is widely used for soldier-worn applications.

  • Low Skew and Propagation delay
  • Extended Bandwidth (increased headroom)
  • Gigabit Ethernet (1000Base-t)
  • Excellent cross-talk characteristics
  • Stranded conductors for Soldier-worn Applications
  • High Strength alloys for Soldier-worn Applications
  • #24, #26, #28  and Micro Patch constructions available
  • 2/pr, 4/pr, 6/pr and bundles available
  • Polyolefin(Riser) or Fluoropolymer(Plenum) insulation
  • Cross Web Separator
  • Color Code Per TIA-568-C.2
  • Double and Triple Threat Shield designs
  • Crush and Cut Resistant TPE Jacket
  • Extra Rugged – Dual Jacket Options Available
  • Halogen-free and Low Smoke, Zero Halogen constructions available
  • PoE Type Hybrid PWR + Data Designs allowing more than 48VDC (Sim. To IEEE 802.3af)
  • Coil Cord Designs Available
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow

Available Compliance and Testing:

  • RoHS Compliant
  • Tested to 350 MHz
  • Electricals Per ANSI/TIA 568-C.2
  • Most constructions ETL Verified ANSI/TIA-568-C.2
  • UL Listed Type CMR
  • UL Listed Type CMP
  • c(UL) Type CMP
  • IEEE 1202
  • UL Subject 444 Communications Cables
  • NFPA 262, Plenum Flame Test
  • ICEA S-102-700
  • NEC Article 800
  • California State Fire Marshal

Ruggedized DisplayPort

Cable USA manufactures standard and mini DisplayPort cables, built to DisplayPort 1.2 standard. Our cable carries a digital audio/video signal with up to 1080p signal.  Our rugged military cable is designed to support rugged tablets, laptops, computers and tactical displays.

  • Ruggedized against EMI / RFI
  • Enhanced Flex-Life
  • Bonded Strength Members
  • Crush and Cut Resistant TPE Jackets
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
Light weight micro and miniature coax cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Soldier-Worn Systems

Light Weight 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 Cameras, 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.

Night Vision and Infrared Optics

We offer an extensive line of micro and miniature sized coax cable that can be bundled with power lines 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

Tactical Tablet and Smart Phone

Miniature and Micro sized rugged display, data and audio cables or coil cords that deliver situational awareness by allowing access to GPS, Voice, Video, Apps, Chat and real-time data.

  • Hybrid PWR + Data Constructions to support C4ISR
  • 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

Aircrew 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 straight 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
  • 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, 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
  • 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

Light Weight Handheld and Body Mounted Devices

Miniature and Micro sized rugged display, data and audio cables or coil cords that deliver situational awareness by allowing access to GPS, Voice, Video, Apps, Chat and real-time data.

  • Hybrid PWR + Data Constructions to support C4ISR
  • 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

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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