Website review
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What is OnlineCables?
OnlineCables is the online ordering and custom-design site of Applied Interconnect Inc., a US cable-assembly manufacturer. It is aimed at engineers and buyers who need RF coaxial cable assemblies built to order rather than off-the-shelf parts. The site lets you configure an assembly with your own part numbers and logos, save the drawing, and order it; the company also builds RF delay lines, phase-matched assemblies, military harnesses and M38999 connectors, plus custom overmolds and connector materials.
Who it suits
- RF and hardware engineers specifying semi-rigid, flexible, conformable or Heliax-style coax with SMA, BNC, TNC, N, SMP, MMCX and similar connectors.
- Defense and aerospace buyers who need a supplier with ISO-9001:2015 certification, J-STD-001 soldering certification, ITAR registration and a history on military programs.
- Low-to-mid volume projects: the stated minimum order is $150, with standard delivery quoted at 2–4 working days after receipt of order, so it is not a one-off hobbyist source.
Trade-offs to weigh
The online configurator speeds up quoting and drawing control, but custom assemblies still depend on the vendor's lead time and on you getting the interface, length and bend requirements right. Certification and military pedigree matter if you are selling into regulated programs; for a quick prototype on a tight budget, a distributor with stocked standard cables may be simpler.
As a next step, sketch your assembly—connector types on each end, cable type, length, and any phase-matching or marking needs—then use the site's design tool to generate a drawing and confirm the minimum order and lead time before committing.
How do I design and order a custom RF coaxial cable assembly online?
Start with the design tool on OnlineCables, which lets you specify a custom RF coaxial assembly using your own part numbers and logos and save the resulting drawing. From there the practical path is: choose the cable type and connector series, confirm the electrical and mechanical requirements, submit the drawing for a quote, then place the order.
What to decide before you start
- Cable construction: the site lists semi-rigid, flexible, conformable coax, VNA cables, Heliax and circular/military assemblies. Your frequency range, loss budget and how much the cable must bend will point to one of these.
- Connector series: options include SMA, SSMA, BNC, SMP, TNC, N, MMCX, MCX, SMB, SSMB, F, UHF, SMC and SSMC, plus MIL-STD-38999 connectors for harness work.
- Assembly-level services: if phase stability matters, ask about phase matching and RF delay lines, which the site offers alongside the cables themselves.
- Documentation: the design tool produces a saved drawing with your part number and logo, which is what you would attach to an internal requisition or send to a colleague for approval.
What the supplier states about ordering and quality
The page gives a $150 minimum order and standard delivery of roughly 2–4 working days after receipt of order, and invites calls for specials not listed on the site. It describes ISO-9001:2015 certification, J-STD-001 and RoHS compliance, IPC/WHMA-A-620 workmanship for commercial product, and a history of military and aerospace programs. Treat these as the supplier's own claims to verify against your procurement requirements, particularly if you need ITAR-controlled data handling or traceability paperwork.
A worked example
Suppose you are building a test rack for a 6 GHz radio and need eight short jumpers with SMA plugs, each labeled with your lab's asset number. You would pick a flexible coax, select SMA connectors, enter the length and your part-number scheme, save the drawing, and confirm the total clears the minimum order. If the rack later needs a matched set for phase-sensitive measurements, that is the point to ask about phase matching rather than ordering standard jumpers twice.
Next step
Prepare three things before using the design tool: a frequency and loss target, a connector interface list, and a part-number convention. If any requirement falls outside the listed options, such as a custom connector material or a waveguide adapter, call the number on the site rather than forcing a near-match into the configurator.
What is the minimum order size and typical lead time for custom cable assemblies?
The stated minimum order is $150, and standard delivery is typically 2–4 working days ARO (after receipt of order). Both figures come from the site's own text, so treat the lead time as a standard-product estimate: assemblies marked "special," custom connectors, harnesses, or military programs are likely to need a quoted schedule.
What this means in practice
- Prototype and small-batch buyers: the $150 floor is low enough for a single engineering sample or a short pilot run, which suits bench testing and design validation.
- Production buyers: the 2–4 day window is useful for urgent replacement or line-down situations, but confirm it against your actual part before committing to a delivery promise. Complex items such as phase-matched or delay-line assemblies and M38999 harnesses usually carry longer schedules.
Next step
Use the site's online design tool to build your assembly with your part numbers and logo, save the drawing, then call 408-749-9900 to confirm the lead time and whether your configuration falls under the minimum order. If you need a second source for comparison, check Digi-Key or Mouser for standard coaxial assemblies, though neither matches this site's build-to-drawing model.
Which military and aerospace programs have these cable assemblies been qualified for?
The page names several military and aerospace programs that Applied Interconnect, the company behind OnlineCables, says its cable assemblies and related work have supported. These are program references the company lists as part of its credentials, not detailed qualification reports.
Programs named on the site
- Missiles and munitions: AMRAAM (Advanced Medium Range Air to Air Missile) and HARM (High-Speed Anti-Radiation Missile).
- Aircraft: F-35 Joint Strike Fighter, F-18 with the APG-79 radar, B-2 with the APQ-181 radar, and the Apache helicopter.
- Unmanned and space: Global Hawk and GPS flight hardware.
- Other platforms: Airborne Laser (ABL), M1A1 Tank, and M2 Bradley.
- Government customers: the site describes Applied Interconnect as a prime military contractor for the US Air Force, NASA, US Navy, US Army and the Government of Canada.
What backs these claims
The page ties the program list to certifications rather than to per-program test data. It cites ISO-9001:2015 quality certification (cage # 0X997), J-STD-001 soldering certification, RoHS compliance, IPC/WHMA-A-620 workmanship for commercial product, and registration under US/Canada Joint Certification for Military Critical Technical Data with ITAR requirements.
How to use this
If you are sourcing for a defense or aerospace build, treat the program list as a starting point for a conversation, not as proof of qualification for your specific part. Ask for the qualification documentation relevant to your program, such as test reports, screening level and traceability for the exact assembly you need. The site's configurator is useful for specifying connectors (SMA, BNC, TNC, N, MMCX and others) and cable types, but confirm program-specific qualification directly with the company before relying on it.
Can OnlineCables produce custom connectors or assemblies that aren't listed on the website?
Yes. OnlineCables states directly that if you cannot find what you need on the website, they do specials and invites you to call (408 749-9900). The site also lists custom work beyond standard catalog parts: custom connectors in stainless steel or other materials, custom assemblies such as waveguide adapters, filters and power distribution assemblies, plus custom cable assemblies using silicone, PTFE, ETFE, FEP and Estane. So a non-catalog connector or a one-off assembly is within the stated scope.
What this means in practice
The online design tool covers the standard RF coaxial assembly range (SMA, BNC, TNC, N, MMCX and similar connectors, semi-rigid, flexible, conformable and Heliax cable, delay lines and phase matching). Anything outside that—a non-standard shell material, a mixed harness, a waveguide adapter—moves to a conversation rather than a self-service order. The page notes a $150 minimum order and typical delivery of 2–4 working days after receipt of order for standard work; treat the lead time quoted for a special as the one that applies to your job.
A realistic scenario: an engineer needs an SMA assembly with a stainless-steel body and a custom mounting flange for a radar test fixture. The flange variant is not in the drop-down menus, so the practical route is to call with a drawing or a description, confirm material and plating, and ask for the drawing back for approval before production.
Decision criteria
- Standard connector, standard cable: use the online configurator; fastest path.
- Standard connector, unusual material or plating: ask by phone; confirm the material spec in writing.
- Multi-branch harness or mixed RF/power/fiber: request a custom quote with a schematic.
- Qualification-sensitive programs: the site cites ISO-9001:2015, J-STD-001, IPC/WHMA-A-620 workmanship and ITAR registration, so ask which of these applies to your specific assembly.
For comparison on standard catalog parts and lead times, see OnlineCables.
What connector types and cable categories are available for RF assemblies up to 40 GHz?
OnlineCables lists a broad connector set for RF assemblies up to 40 GHz: SMA, SSMA, BNC, SMP, TNC, N, MMCX, MCX, SMB, SSMB, F, UHF, SMC, and SSMC, plus MIL-STD-38999 circular connectors for harness work. Cable categories on the site include semi-rigid, flexible coax, conformable coax, VNA cables, Heliax, and circular/military harnesses, alongside RF delay lines and phase-matched assemblies.
Matching connector to cable type
- Semi-rigid: SMA, SSMA, and SMP suit the tight tolerances and phase stability usually wanted in semi-rigid runs; this is the typical route for phase-matched or delay-line builds.
- Flexible and conformable coax: BNC, TNC, N, and UHF are the common choices where repeated handling or field routing matters more than loss.
- Miniature and board-level: MMCX, MCX, SMB, SSMB, SMC, and SSMC fit dense packaging where space is the constraint.
- Harness and ruggedized runs: MIL-STD-38999 connectors pair with the circular military harness offering.
Practical selection criteria
Frequency is only the first filter. Decide whether you need phase matching or delay-line performance (which pushes you toward semi-rigid and tighter connector families), whether the assembly will be flexed in service (favoring flexible coax with BNC/TNC/N), and whether the interface must mate with existing equipment (which often settles the connector before the cable). The site notes a $150 minimum order and standard delivery of roughly 2–4 working days ARO, with specials available by phone.
For a first step, sketch the interface at each end and the routing environment, then use the site's online configurator to build the assembly with your part numbers and save the drawing for review. If your frequency sits near the top of the 40 GHz range, confirm the specific connector–cable pairing rather than assuming any listed connector covers the full band.
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