Selecting the correct aviation cable model is critical for aircraft performance, safety, and compliance. This guide provides a detailed breakdown of common aviation cable types, their specifications, and typical use cases in aerospace systems.
**1. MIL-SPEC Cables: Military and Commercial Standards
These cables meet stringent U.S. military specifications and are widely used in both defense and commercial aviation:
Model Specification Key Features Applications
MIL-DTL-27500 Teflon-insulated High-temperature resistance (200°C), chemical resistance Engine sensors, avionics
MIL-DTL-22734 Coaxial cable EMI shielding, lightweight Radar, communication systems
MIL-W-5086 Tinned copper conductor Corrosion-resistant, flexible Cockpit wiring, lighting
Note: MIL-SPEC cables often include suffixes like “/1” (unshielded) or “/3” (braided shield).
**2. SAE AS Standards: Aerospace-Specific Models
The SAE AS series defines cables for civil and military aircraft:
SAE AS22759:
Subtypes: AS22759/11 (unshielded), AS22759/41 (shielded).
Features: ETFE insulation, 150°C rating, lightweight.
Uses: Flight control systems, fuel pumps.
SAE AS4373:
Subtypes: AS4373/5 (fiberglass braid), AS4373/8 (silicone jacket).
Features: Fire-resistant, low smoke.
Uses: Emergency systems, cabin wiring.
**3. European Norms: Airbus and EN Specifications
Airbus and European standards prioritize weight savings and environmental resistance:
EN 3475-100:
Model: EN 3475-506 (shielded, PTFE insulation).
Features: Halogen-free, -65°C to 260°C range.
Uses: Airbus A320/350 hydraulic systems.
Airbus AIMS 09-0020:
Model: AIMS 09-0020-15 (composite conductor).
Features: 30% lighter than copper, high flex cycles.
Uses: Wing flap actuators, landing gear.
**4. Specialized Aviation Cable Types
A. High-Temperature Cables
Model: PTFE/Nomex hybrid (MIL-DTL-87104).
Temp Range: Up to 400°C.
Applications: Engine bay, APU (Auxiliary Power Unit).
B. Fiber-Optic Cables
Model: D38999/24 fiber-optic bundle.
Features: Immune to EMI, high data transmission speeds.
Uses: In-flight entertainment, flight data recorders.
C. Fire-Resistant Cables
Model: SAE AS23053/3 (LSZH jacket).
Features: Self-extinguishing, low toxicity.
Uses: Emergency lighting, oxygen systems.
**5. How to Decode Aviation Cable Model Numbers
Aviation cable models follow standardized naming conventions:
Example: MIL-DTL-27500/16T13
27500: Base specification (Teflon-insulated).
16: Wire gauge (16 AWG).
T: Tinned copper conductor.
13: Shield type (foil + braid).
**6. Choosing the Right Model: Key Considerations
Match your aircraft’s needs to cable specifications:
Temperature: Engine areas require MIL-DTL-27500 or EN 3475-506.
Weight: Opt for aluminum (AS4373) or composite (AIMS 09-0020) in non-critical systems.
Flexibility: High-cycle zones (e.g., landing gear) need silicone-jacketed (SAE AS4373/8) cables.
Shielding: Avionics demand shielded models (e.g., SAE AS22759/41).
7. Top Manufacturers and Product Lines TE Connectivity: Raychem MIL-SPEC series. Amphenol Aerospace: 38999 coaxial connectors. Prysmian Group: Airbus-compliant EN 3475 cables. 8. Future-Proof Cable Models
Smart Wires: Integrate health-monitoring sensors (e.g., TE’s Cablescan).
Sustainable Models: Recyclable insulation (e.g., Prysmian’s EcoFly).
Aviation Cable Model Comparison Table
Application Recommended Models Key Advantage
Cockpit instruments MIL-DTL-27500/22T11 Signal integrity, compact size
Engine sensors SAE AS22759/41 (shielded) High temp, EMI resistance
Wing de-icing systems EN 3475-506 + PTFE jacket Lightweight, chemical resistance
In-flight Wi-Fi D38999/24 fiber-optic High-speed data, no interference
Premium Aviation Cables for Aircraft Systems: Elevating Safety and Performance In the demanding world of aviation, reliability and precision are non-negotiable. Premium Aviation Cables for Aircraft Systems are engineered to meet the r.
Product Overview: aviation cable Machine vision cables are specialized components designed to ensure high-speed, stable data transmission and signal integrity in automated imaging systems. Key features include: Technical Specifica.
From commercial airliners to military drones, aviation cables are the unsung heroes ensuring reliable power, data, and signal transmission in the skies. These specialized cables are engineered to withstand extreme conditions—think turbule.
Designed to meet the rigorous demands of modern aviation and defense systems, Lightweight MIL-SPEC Aviation Wiring Cables represent the pinnacle of reliability, durability, and performance. Engineered to comply with stringent military sp.
When it comes to aviation safety and performance, every component must meet the highest standards—especially electrical systems. High-Temp Resistant Aviation Electrical Cables are engineered to deliver unparalleled durability and reliabi.
