• • • CABLES • • •


The engineering trade-offs Designing a cable that intertwines both performance and resilience takes calculated compromise. To strike this balance, everything from material selection to technical specifications must be considered to establish competing priorities. High-bandwidth cables are constructed with


precision. Low loss dielectrics, tightly wound foil shielding and copper alloy conductive cores amount to high performing flexible cables, but limitations arise from their lightweight nature making them less rugged. Foil shielding for example, while it serves as an efficient mitigation method for EMI suppression, it can crinkle or even tear under vibration. In an aircraft, vibration is a frequent occurrence meaning that such cable systems need to be able to withstand the shock otherwise they fail. On the other hand, resilient cables encounter


trade-offs with mechanical flexibility. Thicker jacketing and heavy insulators make them heavier, less space efficient and harder to route. In an aircraft, flexibility is essential for routing through tight bends and spaces, so while these ruggedised cables withstand the constant vibrations, they’re insufficient for some aircraft applications like avionics bays and line-replaceable units (LRUs) which are confined and require cables to bend sharply without causing signal loss. When it comes to both performance and


resilience individually, a cable can meet all of its specifications on paper yet still fail in the field.


Combatting this requires engineers to consider application context; understanding where the cable will be used, external factors, is it for a temporary mission or expected to last for 30 years and what happens if it fails? By understanding the operational context as


well as tech-specs, engineers can make smarter decisions about design, materials, shielding and routing to ensure suitable levels of both durability and performance.


Delivering application-specific


connections When designing cables beyond performance specs, engineers must pay attention to materials that withstand the real-world conditions of the application with shielding, and jacketing falling into key consideration areas. In shielding, materials often facilitate reduced


EMI and radio-frequency interference (RFI). Although it also plays a role in a cable’s mechanical structure and physical resilience. For example, foil shielding comprised of aluminium-polyester tape combined with braided shields uses the properties of both features to optimise performance and durability. Braiding acts as an additional layer which protects the thin foil from vibration damage, ensuring high-frequency EMI protection and physical resilience. Extra levels of armour come from jacketing, both


PUR and Perfluoroalkoxy (PFA). Suitable for dynamic defence applications like naval vessel galleries, PUR and PFA offer a low smoke


alternative to polyvinyl chloride (PVC). While both have similar properties, providing exceptional fluid resistance and chemical inertness, PFA is superior from a temperature perspective operating in up to 260°C and PUR offers greater abrasion resistance with many PUR-jacketed cables meeting IP67–IP69K ratings. Each resilient feature can be moulded to fit the


context of an application. When configuring aerospace and defence cable solutions, WireMasters collaborate closely with engineers who require both performance and reliability. By understanding the real-world case, whether it’s mission critical application or a static control interface, a realistic balance is achieved. As a Mil-Spec cable specialist, WireMasters expand on knowledge and experience working in the defence sector to build on solving these complex trade-offs intelligently and reliably. The future could see further developments in


current innovations across the market. Both miniaturisation and hybrid cable configurations, hold promise in enabling lightweight components that are both powerful and resilient enough to handle critical aerospace and military systems even in the world’s most ruthless environments. But right now, whether it’s for a next-gen satellite or military ground communication system, engineers must adopt an application devoted approach in building smarter, long lasting cable systems for these industries.


www.wiremasters.com


electricalengineeringmagazine.co.uk


ELECTRICAL ENGINEERING • SEPTEMBER 2025 13


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52