Cable structures can be formed for cables and other components that include non-cable components such as jacks and headphones. The cable structure includes an outer jacket that is formed from a silicon polymer-based material that is extruded to form a jacket that completely encapsulates a conductive bundle. The cable structures utilizing silicon polymer-based materials can be simple two-ended cables or they can include several legs connected at a point of bifurcation. The extrusion process can be used to manufacture the multiple legs even if they are to be formed of different dimensions. As the silicon polymer-based material is processed by an extruder, one or more system factors of the extruder can be dynamically adjusted to change the diameter of the resulting leg (e.g., to provide a smooth leg having a changing size).