• • • DEFENCE TECHNOLOGY • • •
WHY HIGH-DURABILITY WIRING MATTERS: UNDERSTANDING THE FOUNDATIONS OF RELIABILITY IN
AEROSPACE AND DEFENCE High-durability wiring is fundamental to aerospace and defence platforms, where performance and safety depend on reliability under constant stress. Harnesses endure relentless vibration and abrasion, while also facing sudden temperature shifts from ground level to altitude. By Rush Holladay, Director, Wiremasters
A
ny weakness can compromise mission readiness or disrupt data integrity. Materials and standards have evolved to prove resilience in such conditions, yet new pressures continue to emerge. Here, company Director, Holladay, explains why durability remains central to long-term system performance.
Defining durability
High-durability wiring is designed to resist constant physical wear. When harnesses are routed through confined spaces, adjacent conductors rub against one another for the entire duration of a mission. If insulation wears away, even slightly, the result can be arcing or sparking that threatens the safety of the platform. Unlike static installations in buildings, aerospace and defence wiring is in perpetual motion, subject to repeated torsion and shock that accelerate abrasion. Durability in this context means insulation that withstands these stresses without degradation, preserving both electrical integrity and mechanical stability.
Materials and testing Material selection is central to durability. Cross-linked ethylene tetrafluoroethylene (ETFE, often known as Tefzel) is widely regarded as a robust insulation, valued for its toughness and its ability to resist wear, and is commonly specified in Mil-Spec wire and cable. Irradiated polyalkene and fluoropolymer materials such as PTFE also play a role, depending on the location within the platform and the balance required between resilience and thermal performance. These insulations are often supplemented by secondary measures such as protective sleeving or braided shields, with thermal wraps added when higher levels of defence are required, all part of the wider set of harness management. Durability is proven through rigorous testing. Standard methods subject wires to repeated abrasion cycles under load, often with a hardened steel needle that scrapes across the jacket until the conductor is exposed.
Other regimes examine tensile strength or thermal shock resistance, while additional
resulting downtime can stall assets worth hundreds of millions and delay mission schedules measured in days or weeks.
Signal integrity is another dimension that cannot be overlooked. Modern platforms rely on a dense web of sensors and cameras, with communications systems linking them together. Data flowing through these networks must remain accurate and fast, free from the distortions that damaged insulation or degraded shielding can introduce. Durability, therefore, underpins both operational safety and functional performance.
procedures verify dielectric resistance. This level of scrutiny ensures that when wires are specified to a standard, their performance is demonstrated under controlled conditions.
Standards and compliance Within aerospace and defence programmes, AS22759 remains a defining specification. It encompasses a wide range of constructions, each governed by strict requirements on insulation type, conductor material, shielding and test regimes. Only manufacturers qualified to the Qualified Products List (QPL) are permitted to supply to this standard. Independent verification bodies conduct sample testing and process audits, followed by inspections that confirm every production run remains compliant.
Compliance is not limited to Mil-Spec. Aviation authorities like the FAA require assurance that wiring systems meet safety expectations, particularly when newer cable types, including high-speed data lines, fall outside legacy specifications. This layered framework reflects the industry’s recognition that wiring is as safety- critical as engines or avionics.
Why durability matters in practice
The consequences of poor durability reach into every aspect of programme performance. A wiring fault may cost only thousands to fix, yet the
10 ELECTRICAL ENGINEERING • NOVEMBER 2025
Emerging pressures Materials science and regulation continually reshape how cables are designed and specified. One current pressure is the global scrutiny of PFAS, the so-called forever chemicals that have long been used in fluoropolymer insulations. These substances deliver unique performance at high temperature, yet regulators are pressing for restrictions in consumer and industrial applications. Aviation stakeholders are calling for exemptions, but uncertainty persists. Engineers will need to weigh current performance against the prospect of future substitution. Another challenge is electrification. The rise of electric aircraft and drones brings requirements for cables that can carry higher voltages without excessive weight.
Balancing current-carrying capacity with mass reduction is now a front-line issue for designers seeking to push flight endurance and payload capacity further.
High-durability wiring is the silent guarantor of
performance in aerospace and defence systems. It continues to function under vibration and abrasion, withstands severe temperature shifts and meets the evolving demands of electrification. It safeguards safety while enabling the reliable flow of data that modern platforms depend on. As regulatory and technological landscapes shift, the durability of wiring will remain not just a desirable trait but an operational necessity.
https://www.wiremasters.com
electricalengineeringmagazine.co.uk
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