BNC Connectors for Broadcast Camera SDI Interfaces in the United States

Project Background

The U.S. professional broadcast equipment market is rapidly adopting 4K ultra-high-definition workflows. Broadcast cameras used for live sports, news coverage, and large-scale events rely on SDI interfaces to deliver stable, high-bandwidth video signals. As resolution and data rates increase, the performance of SDI connectors has become a key factor affecting image quality and system reliability.

During the development of a new 4K broadcast camera platform, limitations were identified in conventional BNC connectors, including signal attenuation, limited resistance to electromagnetic interference, and insufficient durability under frequent use. To ensure broadcast-grade performance, a customized BNC connector solution was implemented to upgrade the SDI interface and support long-distance, loss-free 4K signal transmission.

Application Challenges

The camera system was designed for demanding environments such as outdoor sports events and mobile production units. The main challenges included:

High-bandwidth transmission requirements: 4K SDI signals require precise 75-ohm impedance matching to prevent image degradation over long cable runs.

Electromagnetic interference: Wireless communication equipment and high-power lighting systems in broadcast environments can disrupt signal stability.

Environmental exposure: Outdoor filming involves temperature fluctuations, humidity, and occasional rain, requiring reliable mechanical protection.

Frequent connection cycles: Broadcast workflows involve repeated setup and teardown, placing high demands on connector lifespan and contact stability.

Standards compliance: The solution needed to meet U.S. and international broadcast and electronic equipment regulations.

BNC Connector Solution

The customized BNC connectors were optimized specifically for 4K SDI applications.

A precision 75-ohm impedance design, using copper-alloy conductors and PTFE insulation, controls impedance deviation within ±1 ohm. This ensures stable transmission of 12 Gbps 4K SDI signals with no visible loss or distortion over distances of up to 150 meters.

To improve signal integrity in complex environments, a dual-layer shielding structure was adopted, combining a silver-plated copper foil layer with an outer braided shield offering more than 95% coverage. This significantly reduces electromagnetic and radio-frequency interference.

For outdoor reliability, the connectors feature gold-plated contacts and a reinforced housing made from high-performance engineering materials. With an IP54 protection rating and an operating temperature range from –40°C to +85°C, the connectors maintain stable performance in both studio and field-production conditions. The optimized contact structure supports over 10,000 mating cycles, reducing maintenance and replacement frequency.

Key Technical Specifications

Impedance: 75Ω (±1Ω)

Data Rate: Up to 12 Gbps (4K SDI)

Transmission Distance: Up to 150 m

Shielding Coverage: ≥95%, error rate ≤10⁻¹²

Protection Rating: IP54

Operating Temperature: –40°C to +85°C

Mating Cycles: ≥10,000

Compliance: FCC, CE, RoHS

Results and Industry Value

After implementation, the upgraded SDI interface delivered stable 4K video with no signal interruptions or image artifacts during live broadcasts and recordings. Enhanced shielding and durability reduced connector-related failures and maintenance costs.

This BNC connector solution improves the reliability and competitiveness of broadcast cameras in the U.S. market and is also suitable for other professional SDI-based video systems, including mobile broadcast units and production studios.