A headset can include a cable structure connecting non-cable components such as jacks and headphones. The cable structure can include several legs connected at a bifurcation. An extrusion process can be used to manufacture legs of a multi-segment cable structure. As material is processed by an extruder, one or more system factors of the extruder can be dynamically adjusted to change a diameter of the resulting leg (e.g., to provide a smooth leg having a changing size). Once the leg is extruded, portions of the leg can be reformed to create undercuts used to connect the legs at a bifurcation region. In some cases, an extrusion process can be used to construct a jointly formed multi-leg cable structure having an integral bifurcation region and split.