Considerations To Be Made While Manufacturing Aerospace Cables

Considerations To Be Made While Manufacturing Aerospace Cables

Everything has gone automatic and electronic today; and every appliance and machinery requires cables to run. Simple machineries require fewer cables, while complex machineries may require hundreds of cables connected together to help the equipment to perform. One such field that requires complex machinery and a multitude of cables is the aerospace industry. Cables in the aerospace industry are used widely in a variety of applications like data, power, Ethernet, fiber, video, and more. All these cables must be designed carefully to comply with all kinds of environmental, weight, and safety requirements. Large aircrafts require more than 100 miles of cables, resulting in weighing more than a thousand kg! Thus, lesser the cable weight, lesser the weight of the aircraft, and more economical will the aircraft fuel consumption be, ultimately resulting in greater speed. Also, aircrafts fly through varied kinds of environments from hot to cold, and dry to humid or foggy. The cables used within the aircraft must be able to adapt to each type of situation, while also working efficiently at all times. So, you can see how small cable constructions and selections require so much of detailed analysis for an aircraft.  There is a lot more to consider while selecting and designing cables for the aerospace industry; some of the considerations mentioned below.

Surface properties

Aircraft cables must be easy to mark, which means that the must be smooth and receptive to label adhesion. This is because there are hundreds of wires within an aircraft, and you can’t afford to note down the individuality of every wire separately. And, if anything goes wrong while joining the wires into the circuit, you can imagine the amount of damage!


As mentioned above, the cables used in an aircraft must be light in weight to reduce the weight of the vehicle. By utilizing cables with a higher temperature rating, the weight of the aircraft can be reduced. This is because these cables require lesser copper, thus they weigh less. Also, incorporating improved insulation can minimize the weight.


Above mentioned are the most common environmental conditions aircraft cables may have to encounter, namely heat, cold, humidity, dryness, rainfall, and snowfall. But, other than this, they are also likely to face exposure to fluids, abrasion, vibration, pressure, and moisture.


It is very important that aircraft cables emit minimal smoke and dangerous gases in case they are exposed to fire, or you can imagine the dreadful results!

Overload conditions

It is quite possible and common for aircrafts to face overload conditions, with the pressure being transferred to the cables as well. Thus, it is important that the cables used must be able to maintain circuit integrity in case of a current overload situation.

Electromagnetic Interference

Aerospace cables must adhere to the required Electromagnetic Interference requirements. For this, the cables must follow these guidelines.

  • They must use minimum braided shielding, and maximize the use of foil.
  • They must provide sufficient grounding at both cable ends to chassis ground.
  • They must use filtered connectors.
  • They must use twisted data signal wires, will help to cancel out emission fields.
  • They must shield the cable signals and minimize the transfer impedance.

You can see how everything must be analyzed in detail before manufacturing an aerospace cable. This is why you must purchase your aerospace cables from reputed and reliable professionals. Miracle Aerospace tops the list of such aircraft cable assembly manufacturers in India with a team of certified engineers, automated machineries, in-house manufacturing capabilities, and lean manufacturing processes that are utilized in constructing cables from UL approved and MIL grade materials.