What does wire and cable assembly for the aerospace industry mean?

The aerospace industry relies on wire and cable assembly for many different functions. It is a sector where innovative design and high standards of performance are a given and environments can be harsh and unforgiving. Designing and manufacturing wire and cable assembly for the aerospace industry requires a wealth of experience as well as the ability to deliver to the highest specifications.

Wire and cable assembly for the aerospace industry

Wire and cable assemblies are used in many different ways across the aerospace industry. These include standard wires and cables, as well as custom designed wires and cables. A few of the types of wires and cables that are generally found across the aerospace industry include MIL-W-16878, MIL-W-81044 and MIL-DTL-27500. Cable assemblies and wire harnesses are vital components for designs across the sector. These can be used in a broad spectrum of different applications, including avionics, satellite systems, airframe, missile systems and in-flight entertainment systems.

Key considerations for the aerospace industry

Wire and cable assembly for this sector has to be specifically designed as the environments can be harsh and the specifications stringent. Standard wires and cable assemblies may simply not meet the required standards of design and performance, which is often why custom cable assembly is the first choice for companies across the aerospace sector. There are many different considerations for wire and cable assembly for the aerospace industry. Some of these include selecting the right wire (usually this is the smallest gauge wire that can easily carry the required current), easy identification of wires in a cable assembly, as well as ensuring that the right connectors are being used for the specific purpose. Bundling and protection are also a vital part of the process of creating wire and cable assemblies for the aerospace industry.

What are the benefits of custom design?

As mentioned, the aerospace sector can require a lot of wire and cable assembly, which is why some off-the-shelf designs may simply not be fit for purpose. Custom design offers a range of benefits that are much more suitable for aerospace components. These include:

• Having much more control over the materials that are used in the wires and cable assembly so that these can be chosen to intentionally meet specifications.
• Increased accuracy as custom cable assembly designs are manufactured to a precision specification and everything is bespoke, from the length of the cables to the colour coding.
• A necessary level of quality assurance. Critical wires and cable assembly can’t afford to fail – the results of this in aerospace could be catastrophic. Custom wires and cable assembly are thoroughly tested for specific environments and to ensure certain levels of resistance e.g. to chemical exposure.
• Higher levels of performance. As they are bespoke and made with carefully chosen components, custom cable assemblies often perform to a higher standard than off-the-shelf options.

Wire and cable assembly for the aerospace industry means producing technically superior, performance-drive components that can withstand harsh environments and extreme use.