Coaxial cables with shaped metallic conductors

A method for manufacturing a coaxial cable, comprising:

• providing a cable core comprising at least one optical fiber encased in a polymeric layer;
• enclosing the encased cable core with a first pair of shaped conductors, wherein the first pair of shaped conductors comprise a first semi-circular-profile shaped metallic wire and a second semi-circular-profile shaped metallic wire, and wherein the enclosing comprises engaging the shaped conductors of the first pair of shaped conductors about the encased cable core at a first pair of opposite joint lines extending along a longitudinal axis of the cable core to form an inner circular profile about the encased cable core;
• extruding an inner layer of polymer over the inner circular profile of the first pair of shaped conductors;
• and
• placing a second pair of shaped conductors about the inner layer of polymer;
• wherein placing the second pair of shaped conductors about the inner layer of polymer comprises forming an outer circular profile of shaped conductors by engaging a first outer semi-circular-profile shaped metallic wire with a second outer semi-circular-profile shaped metallic wire of the second pair of shaped conductors about the inner layer of polymer at a second pair of opposite joint lines extending along the longitudinal axis of the cable core to form the outer circular profile about the inner layer of polymer;
• extruding an outer layer of polymer over the outer circular profile of the second pair of shaped conductors;
• cabling a first armor wire layer about the outer layer of polymer;
• and
• cabling a second armor wire layer about the first armor wire layer to form the coaxial cable.