Advanced materials are building a greener future for aerospace wiring systems
by Jeff Wood, Sales Director at WireMasters
Keeping up with sustainability efforts across the aviation industry is a challenging task. However, reducing environmental impact while maintaining high safety and performance standards is an industry imperative. Aircraft wiring is no exception to this, and manufacturers have begun to implement innovative weight-saving materials, such as aluminium alloy conductors, carbon fibre composites, or polytetrafluoroethylene (PTFE) jacketing, in airborne cable systems.
Weight reduction is a crucial factor in enhancing fuel efficiency and lowering emissions. For each kilogram (kg) of weight reduced, an aircraft saves approximately 0.03kg of fuel per 1,000 kilometres (km), which translates to a saving of around 0.0945 kg of carbon dioxide (CO2) emissions per 1,000 km. Considering this, even the smallest weight change in wiring systems can make a difference.
Distributors play a key role in managing these challenges by collaborating closely with aerospace manufacturers. Broad inventories of advanced, compliant materials and technical support enable aerospace manufacturers to reap the sustainable benefits of a lighter cable system without compromising on safety and performance.
Advanced materials
Traditionally, aerospace cabling has relied on copper thanks to its excellent conductivity. However, its density significantly contributes to an aircraft’s weight, prompting the industry to explore alternative materials without compromising performance.
Aluminium (Al) alloy conductors have infiltrated the market as a popular alternative to copper. Usually comprised of aluminium, copper, iron, and magnesium, each metal’s individual properties contribute to the conductor’s resistance, creep resistance, and strength.
While AI alloys don’t quite match copper’s conductivity, they offer up to 50% weight reduction in wiring applications with the equivalent electrical resistance. This balance of conductivity and weight makes them suitable for avionic systems, improving fuel efficiency, which aligns with the industry’s sustainability goals.
Longevity also plays a role in the aerospace industry’s greener future. Longer equipment lifespans not only save businesses money on maintenance costs but also reduce the need to fully replace old systems. This minimizes electronic waste and reduces the need for frequent raw material extraction, which results in lower carbon emissions.
Similarly, composite PTFE jackets in aerospace wiring enable increased durability and resistance, which are crucial for longer operational lifespans, while reducing footprint and weight.
PTFE jackets offer superior abrasion resistance, chemical resistance, and operational performance in temperatures up to 260°C. This increased durability enables cables to have a service lifespan of up to 30 years, minimizing the need for regular replacement and waste. These jackets also meet the stringent aerospace industry standard AS22759, which ensures insulator performance and quality.
Fibre optic cables are another advancement focusing on both performance and quality. They are lighter than metal-core cables, typically weighing approximately 4 pounds per 1,000 feet, whereas copper cable weighs around 39 pounds per 1,000 feet. Fiber also offers higher bandwidth, supporting transfer speeds of up to 10 Gigabits per second (Gbps) and immunity to electromagnetic interference (EMI).
In aerospace applications, fibre’s improved signal integrity reduces the need for heavy shielding and simplifies cable design. This enables a substantial reduction in an aircraft’s weight, which enhances fuel efficiency without compromising performance or reliability.
Supplying sustainability
Adopting sustainable, high-performance cabling that also meets industry standards is a process accelerated by supply chain partners like WireMasters. We can provide access to advanced materials in high demand, such as composites based on AS22759 standards and high-temperature, halogen-free insulation materials. We also provide technical expertise aligned with the most up-to-date standards and regulations, such as the Restriction of Hazardous Substances (RoHS) or FAR 25 Appendix F, to ensure these materials are used appropriately.
Working closely with OEMs, we can ensure a seamless transition to a sustainable aviation future driven by advanced materials. Supply chain coordination, including forecasting, inventory planning, and demand visibility tools, facilitates this transition, resulting in lighter, more efficient, and durable aircraft wiring systems. The result is more sustainable aircraft cable systems with extended maintenance cycles that contribute to reduced emission goals, such as Jet Zero.