aviation cable factory

Aviation Cables for OEM: Key Considerations for Reliable Aerospace Solutions

In the aerospace industry, Original Equipment Manufacturers (OEMs) rely on every component to meet uncompromising standards of safety, durability, and performance—and aviation cables are no exception. As the backbone of signal transmission, power delivery, and system connectivity in aircraft, these cables directly impact the functionality of critical systems, from avionics and navigation to engine controls. For OEMs, selecting the right aviation cables is not just a procurement decision but a strategic step to ensure compliance, reduce downtime, and maintain the integrity of their end products.

Core Performance Requirements for OEM Applications

Aviation cables must withstand the unique and harsh conditions of aerospace operations. OEMs need to prioritize cables that meet the following non-negotiable performance criteria:

1. Extreme Environment Resistance: Aircraft operate in wide temperature fluctuations (-65°C to 200°C for most applications), high altitude pressure changes, and exposure to harsh substances like jet fuel, hydraulic fluids, and ozone. Cables must use insulation and jacketing materials (e.g., PTFE, FEP, ETFE) that resist degradation under these conditions.
2. Signal Integrity & EMI Shielding: Avionics systems depend on clear, uninterrupted signal transmission. Cables must feature robust shielding (e.g., tinned copper braid, aluminum foil) to block electromagnetic interference (EMI) from other aircraft systems, preventing data loss or system malfunctions.
3. Mechanical Durability: Vibration from engines, frequent flexing during maintenance, and physical abrasion demand cables with high tensile strength and fatigue resistance. Stranded conductors (instead of solid wires) are standard, as they enhance flexibility without sacrificing conductivity.

Compliance & Certifications: Non-Negotiable for OEMs

Aerospace regulations are among the strictest globally, and non-compliant cables can lead to project delays, regulatory penalties, or even safety hazards. OEMs must verify that cables meet industry-specific certifications:

• DO-160 (RTCA/DO-160): The primary standard for environmental testing of aerospace electrical equipment, covering temperature, vibration, humidity, and EMI performance.
• UL 94: A flammability standard that mandates cables self-extinguish quickly to prevent fire spread—critical for cabin and engine compartment applications (e.g., UL 94 V-0 rating for zero flame propagation).
• IEC 60332: Specifies fire resistance for cables, ensuring they maintain functionality during short-term exposure to high temperatures (e.g., IEC 60332-1 for single cables, IEC 60332-3 for bundled cables).
• AS9100: While not a cable-specific standard, OEMs should partner with suppliers certified to AS9100 (aerospace quality management) to ensure consistent manufacturing quality.

A Practical Selection Guide for OEM Engineers

Selecting aviation cables requires aligning technical specs with the OEM’s specific application. Here’s a step-by-step framework:

1. Define the Application Context: Identify the cable’s location (e.g., engine bay, cabin, avionics rack) to determine required temperature and chemical resistance. For example, engine-mounted cables need higher heat resistance than cabin lighting cables.
2. Match Conductors to Power/Signal Needs: Choose conductor gauge based on current load (for power cables) or signal bandwidth (for data cables). Larger gauges handle higher currents, while smaller gauges suit low-voltage signal transmission.
3. Prioritize Customization Flexibility: Many OEM projects require non-standard lengths, connector integrations, or specialized shielding. Partner with suppliers that offer custom cable assemblies to avoid retrofitting or performance gaps.

Quality Assurance: A Must for OEM Supply Chains

Even certified cables can fail if manufacturing processes are inconsistent. OEMs should evaluate suppliers’ quality control (QC) protocols, including:

• Raw Material Testing: Verification of insulation materials, conductors, and shielding for compliance with specs (e.g., tensile strength, dielectric strength).
• In-Process Inspection: Real-time monitoring of extrusion, stranding, and shielding processes to catch defects like uneven insulation or incomplete shielding.
• End-to-End Testing: 100% electrical testing (continuity, insulation resistance) and sample environmental testing (per DO-160) to ensure each batch meets performance standards.

About FRS: Your Trusted Aviation Cable Partner for OEMs

When OEMs need aviation cables that balance performance, compliance, and reliability, FRS stands as a proven manufacturing partner. With over a decade of focus on aerospace-grade cables, FRS delivers solutions tailored to OEM needs:

• Full Compliance: All FRS aviation cables meet RTCA/DO-160, UL 94 V-0, and IEC 60332 standards, with AS9100-certified facilities ensuring consistent quality.
• Customization Capabilities: From specialized insulation materials for extreme temperatures to pre-terminated cable assemblies with OEM-specified connectors, FRS adapts to unique project requirements—reducing lead times and integration effort.
• Rigorous QC: Every FRS cable undergoes raw material audits, in-process inspections, and post-production electrical/environmental testing, guaranteeing zero defects for critical aerospace applications.

For OEMs building the next generation of aircraft, FRS doesn’t just supply cables—we deliver the reliability that keeps systems running, and passengers safe.