Noise control is critical in military and communications cables where signal clarity, intelligibility, and reliability are required in electrically and mechanically demanding environments. Effective noise reduction is achieved through conductor selection, shielding architecture, and controlled construction methods.

Sources of Noise

Common noise challenges include:

  • Electromagnetic and radio-frequency interference (EMI/RFI)
  • Crosstalk between adjacent conductors
  • Triboelectric noise generated by cable motion
  • Grounding and termination inconsistencies

MIL-spec and communications designs address these factors at the construction level.

Shielding Strategies

Shielding is the primary method for reducing external interference.

  • Served or Spiral Shields: Flexible and effective for headset and communications cords
  • Braided Shields: Increased coverage and mechanical durability
  • Conductive PVC Shields: Combine noise reduction with flexibility
  • Combination Shields: Multiple layers for demanding environments

Shield choice balances noise suppression with flexibility and fatigue life.

Conductor and Insulation Effects

Internal cable design influences noise performance.

  • High strand-count or alloy conductors reduce microphonic effects
  • Consistent strand geometry improves signal stability
  • Insulation materials selected to minimize static and handling noise

These factors are especially important in dynamic or wearable applications.

MIL-Spec Considerations

Military cable designs emphasize durability alongside noise control.

  • Compliance with specifications such as MIL-DTL-5898 and MIL-C-10392
  • Rugged jackets and abrasion-resistant materials
  • Proven constructions for flight-line, ground support, and tactical use

Many of these designs are also specified for demanding commercial applications.

Selecting a Noise-Reduction Approach

Effective noise reduction depends on signal sensitivity, motion requirements, shielding type, and environmental exposure. Gavitt works with customers to evaluate these factors and recommend constructions that maintain signal integrity in MIL-spec and communications applications.