A Custom Audio Cable Designed for Wisycom MCR54
For professional wireless audio equipment, cable construction is not only about connector compatibility. The cable itself must also match the electrical requirements of the application.
We recently received a customization request for a TA5F to Dual Low-Profile XLR cable for the Wisycom MCR54, specifically requiring a 110Ω AES digital audio version.
The customer needed a compact cable assembly with:
- TA5F female mini XLR input
- Dual low-profile XLR 3-pin male outputs
- 110Ω AES-compatible cable
- Compact construction for professional audio equipment
- Different connector cap colors for easy identification
The Engineering Challenge
At first, the requested cable could be produced in a conventional Y-split configuration.
However, the 110Ω AES requirement changed the cable construction.
To maintain the appropriate impedance characteristics for AES digital audio transmission, a dedicated 110Ω AES cable was required. This cable uses a 2-core construction, which means it cannot be assembled in exactly the same way as the standard analog version with the conventional Y-shaped split.
Rather than compromising the electrical performance, our engineering team redesigned the cable structure around the requirements of the 110Ω AES cable.
The Final Custom Solution
The final configuration uses:
TA5F Female Mini XLR → Dual Low-Profile XLR 3-Pin Male
Instead of the conventional Y-shaped cable, the finished cable uses a compact V-shaped structure.
This allows the cable to maintain the required 110Ω AES cable construction while still providing two XLR outputs in a compact professional audio format.
The customer also requested one red cap and one blue cap on the two XLR connectors, making the two outputs easier to distinguish during setup and operation.
Final Configuration
Application: Wisycom MCR54
Signal: 110Ω AES digital audio
Connector A: TA5F Female Mini XLR, straight
Connector B: Dual Low-Profile XLR 3-Pin Male
Cable: Dedicated 110Ω AES cable, 2-core construction
Cable Structure: V-shaped split
Connector Identification: One red cap + one blue cap
Why Custom Cable Engineering Matters
A cable may look similar to an existing product, but the internal cable construction, impedance, connector design, and mechanical structure can make a significant difference in professional audio applications.
For this project, simply changing the connectors on a standard analog cable was not enough. The 110Ω AES requirement had to be considered from the cable construction level, which led our engineering team to develop a different physical configuration.
Need a Custom Cable for Your Audio Equipment?
At Alvin’s Cables, we support custom cable solutions for professional audio, broadcast, wireless microphone, camera, and other production equipment.
If you have a specific connector combination, cable impedance, length, wiring configuration, or mechanical requirement, send us your requirements and reference photos. Our engineering team can evaluate the application and develop a suitable custom cable solution.
