Aviation Cable Types and Models
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