Shielded twisted pair cables, in which a pair of conductors of a single circuit are twisted together to minimize electromagnetic interference from outside sources, are widely used.

Example of an Aerospace application:

The specifications called for the use of silver plated copper wire insulated with Teflon® PTFE.

After the wires were insulated with Teflon® PTFE, the cabler was employed to twist the wires into shielded twisted pair cable, which was subsequently wrapped with Kapton® tape. This tape is a polyimide film known for its stability across a wide range of temperatures, and ideal for the conditions frequently encountered in aerospace applications.

After the tape wrap, a 90% coverage SPC shield was applied. The shielded twisted pair cable was finished with a flexible PFA jacket to provide additional chemical and corrosion resistance.

In addition to submitting the cable to both measurement and spark testing, we also verified its integrity by subjecting it to a voltage test at 2500 VAC.

Teflon® is a registered trademark of Chemours and used under license by Micro-Tek.

Aerospace and High-Reliability Applications

These cables are built for systems where EMI can severely impact data transmission. Applications include avionics, sensors, flight control wiring, and data communication systems. The consistent impedance and shielding performance make them a strong choice for high-reliability projects where failure is not an option.

For environments requiring additional signal paths and higher data bandwidth, Micro-Tek offers multi core coaxial cables for signal applications requiring broader bandwidth, and products that incorporate such materials for added resilience. These cables provide similar protection and durability while supporting different electrical requirements. Using both cable types in combination allows system designers to meet varied functional and environmental needs.

Customization Options

Micro-Tek provides flexible manufacturing capabilities to match specific requirements. Options include various conductor sizes, insulation colors, shielding configurations, and jacket types. Whether the application calls for a single shielded twisted pair cable or a more complex build, Micro-Tek can manufacture to the requested specifications.

Production runs range from small prototyping batches to full-scale orders. All cables are made in the USA and built under an ISO 9001:2015-certified quality management system, which supports consistency and reliability across each build.

Why Choose Twisted Pair Cables

  • Reduces electromagnetic interference (EMI) through physical twisting of conductors for your application
  • Maintains signal quality across longer distances with minimal noise intrusion
  • Supports consistent impedance for improved data transmission performance
  • Helps prevent crosstalk between signal lines in multi-pair configurations
  • Offers flexibility for installation in tight or complex spaces
  • Lightweight design makes it suitable for aerospace and mobile systems
  • Compatible with differential signals and low-voltage digital communication
  • Can be shielded for added protection in high-interference environments
  • Simplifies routing and bundling in wire harnesses and assemblies
  • Performs reliably when paired with high-grade materials such as PTFE and silver-plated copper

Why Micro-Tek

Micro-Tek’s experience with fluoropolymer materials and high-performance wire construction gives engineers and purchasing teams confidence in the results. Each shielded twisted pair cable is produced using in-house extrusion and braiding techniques, which helps control quality and lead time.

To discuss your application requirements or request a quote, contact us today. Please include your target specifications, such as conductor count, shielding type, insulation materials, and any environmental constraints. Micro-Tek will help determine the right configuration and provide lead-time and cost information based on your needs.