Abstract: A process for preparing a cathode assembly comprising forming a hanger assembly by inserting an electrically conductive metal hanger core having a curved cross section into a metal tube jacket having a rectangular cross section such that the sides of the metal tube are displaced outward by the outer surface of the hanger core, effecting good electrical contact between the hanger core and the metal tube jacket. One edge of a metal sheet is rigidly attached to the metal tube jacket along its length, perpendicular to the tangent of the outer surface of the metal tube jacket. The cathode assembly produced according to this process has utility in a wide variety of electrolytic manufacturing processes, especially in the electrolytic refining of copper.