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Air dielectric coax cables

Some applications for coaxial cables require transmitting very high power RF energy, strong enough to melt the cables with Teflon inside because of the heat from its resistance.  We build rigid coaxial cable assemblies using wax mandrels with the center conductors inside.  The wax gets melted out after the exterior is electroformed in copper leaving just air between the center conductors and the walls, which has much lower resistance allowing the systems to function.  In this picture a couple have been cut open to show how the center conductor is seated with Teflon spacers.