What Training is Needed to Work with Aviation Cable? Building Expertise for Critical Systems
Working with aviation cable isn’t just about wires and connectors; it’s about ensuring the safety and reliability of complex aircraft systems that carry hundreds of passengers miles above the ground. The stakes are exceptionally high, demanding specialized training far beyond basic electrical work. Whether you’re considering an aircraft technician career, an electrician looking to specialize, or a supervisor managing maintenance, understanding the required training is crucial.
Why Specialized Training is Non-Negotiable
Aviation cables and wiring harnesses are the central nervous system of any aircraft, controlling everything from flight surfaces and engines to navigation and communication. The environment is harsh (extreme temperatures, vibration, pressure changes), and failures can be catastrophic. Training ensures:
- Safety Compliance: Strict adherence to FAA (Federal Aviation Administration), EASA (European Union Aviation Safety Agency), or other national regulations.
- Precision & Reliability: Aircraft wiring requires meticulous workmanship standards absent in other industries.
- Understanding Complex Systems: Knowledge of aviation-specific systems (hydraulics, avionics, fuel, etc.) impacted by wiring.
- Material Knowledge: Understanding unique properties of aviation-grade wires, cables, connectors, and shielding.
- Damage Prevention: Techniques to avoid introducing faults like nicks, chafing, or electromagnetic interference (EMI).
Essential Training Components for Working with Aviation Cable
- Fundamental Electrical & Mechanical Knowledge:
- Basic Electricity: Understanding voltage, current, resistance, Ohm’s law, AC/DC principles, circuits (series/parallel).
- Aviation-Specific Electrical Systems: Learning aircraft electrical generation (generators, alternators), distribution (buses), and unique loads.
- Mechanical Skills: Proficiency with hand tools (wire strippers, crimpers, torque wrenches) and understanding mechanical drawings.
- Regulatory & Standards Training:
- FAA FAR Part 65: Certification requirements for Aviation Maintenance Technicians (AMTs – Mechanics & Repairmen).
- FAA AC 43.13-1B/2B: The definitive guides for acceptable methods, techniques, and practices for aircraft inspection and repair, extensively covering wiring practices. Training focused on interpreting and applying this document is essential.
- EASA Part 66/147: Equivalent requirements for European technicians and maintenance training organizations.
- Relevant SAE Aerospace Standards (AS): Training on specific standards like:
- AS50881: Wiring Aerospace Vehicle.
- AS/EN/NAS 620: Connector Terminations.
- AS/EN/NAS 81824/25: Cable, Special Purpose, Electrical.
- AS/EN/NAS 21919: Identification Sleeving.
- Specialized Skills Training:
- Wire Stripping & Termination: Precision stripping without conductor damage. Mastering crimping techniques (visual inspection, pull testing) for pins, sockets, splices, and lugs per standards. Solder sleeve usage.
- Connector Assembly & Mating: Handling D-sub, circular, rectangular connectors. Pin insertion/extraction. Backshell assembly, grounding, and bonding. Understanding keying and polarization.
- Wire Routing & Harnessing: Proper use of clamps, ties (lace, tie-wraps), conduit. Maintaining bend radii, strain relief, avoiding chafing points, EMI separation.
- Inspection & Troubleshooting: Visual inspection for damage (chafing, pinching, burns, corrosion). Continuity testing, insulation resistance (megger) testing. Basic fault-finding techniques. Knowledge of EWIS (Electrical Wiring Interconnection Systems) Inspection programs.
- Splicing & Repair: Performing permanent and temporary splices according to AC43.13 or manufacturer data. Proper heat shrink tubing application.
- ESDS (Electrostatic Discharge Sensitive) Handling: Procedures for working with sensitive avionics components to prevent damage from static electricity.
- Manufacturer-Specific Training (OEM): Aircraft manufacturers (Boeing, Airbus, etc.) provide in-depth courses on wiring systems for their specific models and updates.
- Formal Education & Certification Pathways:
- Aviation Maintenance Technician (AMT) School (FAA Part 147): Provides the foundational knowledge and practical skills necessary to qualify for the FAA Airframe & Powerplant (A&P) certification exams. Wiring and electrical systems are a significant component of the Airframe rating curriculum. This is the most common and comprehensive entry point.
- Military Training: Veterans with relevant electrical/avionics specialties often possess highly transferable skills, though they typically still need FAA certifications for civilian roles.
- Community College/Technical Programs: Some institutions offer specific avionics or aviation electrical programs meeting industry standards.
- Apprenticeships: On-the-job training combined with formal schooling, often under the supervision of certified A&P mechanics.
- Manufacturer & Vendor Courses: Specific training offered by companies like Amphenol, TE Connectivity, Safran, or aircraft OEMs on their products and associated installation procedures.
Beyond Basic Training: Continuous Learning
- On-The-Job Training (OJT): Refining skills under supervision on actual aircraft projects is irreplaceable.
- Company Procedures: Mastering the specific maintenance manuals, wiring diagram standards (e.g., ATA 100), and processes of your employer.
- Recurrent Training: Staying updated on regulation changes, technological advancements (e.g., fiber optics, composite structures affecting wiring), and revised procedures.
- Specializations: Deepening expertise in areas like Avionics installation/repair, EWIS management, or complex harness fabrication.
Conclusion
The training required to work safely and effectively with aviation cable is rigorous and multifaceted. It begins with foundational electrical and mechanical knowledge but quickly delves deep into aviation-specific regulations (FAA AC 43.13 is paramount), precise hands-on skills (crimping, termination, routing), OEM procedures, and rigorous troubleshooting techniques. Formal training through FAA Part 147 AMT schools leading to A&P certification is the most recognized pathway, supplemented continuously by specialized courses and practical experience. This investment in training is not just a career requirement; it’s a fundamental commitment to upholding the unparalleled safety standards demanded by the aviation industry for every wire connection made.
