The aerospace industry depends on specialty wires and cables to convey data and carry power in aircraft, flight-control systems, satellites, and many other devices. Due to the harsh conditions of space-bound equipment, aerospace wire and cable must be able to withstand a wide range of environments. When producing parts for the sector, manufacturers must take into account the extreme temperature and pressure fluctuations to which these products will be exposed, along with any corrosive elements.

Carefully selecting rugged materials is the key to producing aerospace parts that will withstand the harsh surroundings that might otherwise degrade traditional metals and plastics. At Micro-Tek Corporation, we utilize fluoropolymers such as Teflon® PTFE, FEP, PFA, and Tefzel® ETFE materials for aerospace applications that can reliably withstand thermal and chemical conditions.

Micro-Tek specializes in highly technical products including wire and cable solutions made in the USA. For over a half-century, we’ve built an extensive product catalog of custom wires and cable products for customers across the globe, with aerospace manufacturing being one of our areas of expertise. We offer such options as jacketed, shielded, cabled, cut, or heat-stripped wire, as well as close OD tolerance management, fine sizes, thin walls, flexible materials, and much more.

Teflon® is a registered trademark of Chemours and used under license by Micro-Tek.

Applications in Aerospace and Defense

Micro-Tek’s wire and cable products are engineered to meet the performance demands of modern aerospace and defense platforms. These systems require precise electrical characteristics, lightweight materials, and consistent performance under stress—attributes that define every Micro-Tek solution.

The company’s cables are used in a range of aerospace technologies, including:

  • Satellites and space vehicles – Lightweight, high-reliability cable systems are critical for orbital and deep-space missions. Micro-Tek products are built to endure temperature extremes, vacuum conditions, and radiation exposure.
  • Avionics and flight instruments – Signal clarity and EMI shielding are essential for flight computers, navigation systems, and onboard communication networks.
  • Aircraft sensors and control units – Micro-Tek provides cabling for both digital and analog sensor systems, including temperature probes, pressure sensors, and actuator feedback loops.
  • Launch systems and ground-based support equipment – Cables manufactured to withstand high vibration, fuel exposure, and wide thermal ranges required for vehicle launches and support infrastructure.

The company’s experience in aerospace cable manufacturing also includes mission-critical defense platforms, such as military aircraft, unmanned aerial vehicles (UAVs), missile guidance systems, and tactical communication systems. These environments demand cable configurations that meet strict electrical, mechanical, and environmental specifications.

Materials and Construction

All products are manufactured using high-quality materials. Conductors include silver-plated copper, nickel-plated copper, copper-clad steel, and specialty alloys. These are paired with fluoropolymer insulations such as Teflon® PTFE, FEP, PFA, and Tefzel® ETFE to offer durability against temperature swings and chemical exposure.

Wires and cables are available in sizes from 10 AWG to 50 AWG, with tight diameter tolerances and wall thicknesses starting at 0.00075″.

Wire and Cable Products for Aerospace

Custom Wire & Cable

Micro-Tek offers manufacturing capabilities to support aerospace applications. Diameter tolerances as precise as ±0.0002″ are achievable, and insulation options are available in a wide range of thicknesses and materials.

  • Wire Sizes: #10 to #50 AWG
  • Wall Thickness: PTFE ≥ 0.0025″, FEP/PFA/ETFE ≥ 0.00075″
  • Insulated/Flat Wire Diameter Tolerance: ±0.0002″
  • Typical lead time: 3–4 weeks

These offerings align with client specifications for custom wire for aerospace, backed by in-house engineering and manufacturing control.

Hook-Up and Sub-Miniature Wire

Micro-Tek produces extruded PTFE-insulated hook-up wire and sub-miniature wire for compact, high-density aerospace applications where weight and space are critical. Options include:

  • Solid and stranded constructions
  • Colors and stripe patterns per project requirements
  • Compliance with MIL‑W‑16878 and NEMA HP‑3/HP‑4.

High-Performance Coaxial Cores

Coaxial cores are offered in multiple dielectric formats:

  • Solid PTFE with dielectric constant ~2.05
  • LD-Tek and Tough-Tek for low-loss, high VoP
  • PHAS-Tek for phase stability
  • VEL-Tek with VoP up to 90%

Available with conductor diameters ranging from 41 AWG to 14 AWG, these are suitable for aerospace RF transmission and signal integrity in critical systems.

Micro-Coaxial Cables

Micro-Tek manufactures custom micro-coaxial cables engineered for precise, high-frequency signal transmission in advanced aerospace and avionics systems. These are available in a range of conductors, insulation, shielding, and outer jacket configurations suited to each application. The cables are designed to deliver stable impedance, exceptional signal integrity, and reliable performance in extreme conditions. With customizable, lightweight, durable constructions, Micro-Tek’s micro-coaxial solutions support a wide range of critical applications where size, reliability, and performance are essential.

  • Finished Outer Diameter: 0.041″ ± 0.003″
  • Impedance: 50 ohms
  • Low-noise design ideal for high-precision applications
  • Minimum Order Quantity: 5,000 ft
  • Typical Lead Time: ~8 weeks

Shielded Twisted Pair Cables

Micro-Tek manufactures shielded twisted pair cables designed for high-reliability signal transmission in aerospace systems. These cables provide excellent protection against electromagnetic interference (EMI) while offering the flexibility and durability needed for demanding environments.

Category Overview

  • Conductor Options: Silver-plated copper, stainless steel, and other alloys
  • Insulation: PTFE with optional color coding for identification
  • Shielding: Silver-plated copper braid (~90% coverage) for EMI protection
  • Wrap Layer: Kapton® tape for thermal stability
  • Outer Jacket: PFA for flexibility and chemical resistance
  • Voltage Testing: Supports up to 2,500V
  • Custom Configurations: Available in various conductor sizes, twist rates, shielding types, and colors

Example Configuration – Featured Product

This construction represents one of the most commonly used aerospace cable builds:

  • Conductors: PTFE-insulated, silver-plated copper
  • Shielding: ~90% silver-plated copper braid
  • Wrap: Kapton® tape
  • Jacket: PFA
  • Voltage Rating: Tested to 2,500V
  • Application: Designed for EMI-sensitive communication pathways in aerospace electronics

High-Flex Braided Cable

For environments with frequent movement or vibration, Micro-Tek provides high-flex braided cable built from fine-stranded OFHC copper.

  • FEP insulation and silver-plated copper shielding
  • Outer diameter ~0.100″
  • Ideal for sensor assemblies, vacuum instruments, and movable components
  • Standard production minimum: 5,000 ft

Manufacturing Process and Testing

Micro-Tek’s manufacturing capabilities include:

  • Fluoropolymer extrusion
  • Fine-wire stranding and cutting
  • Taping, bonding, and custom jacketing
  • Stripping, tinning, and precision assembly

Every product is thoroughly tested using spark testing, laser measurement, bond strength analysis, and physical inspections. This focus on performance verification supports long-term reliability in aerospace environments.

Serving the Aerospace and Military Markets

Micro-Tek is a custom aerospace cable company that supports OEMs, integrators, and Tier 1 suppliers serving both civilian and military aircraft programs. Production takes place entirely in the United States under rigorous quality controls.

By specializing in custom military and aerospace cables, the company maintains the flexibility and capability to fulfill project-specific wire configurations, batch quantities, and documentation needs.

Engineering Support and Custom Orders

Micro-Tek works directly with clients to define specifications, material preferences, insulation types, and wire gauges that match the operational demands of each aerospace system.

  • Minimum production runs begin at approximately 1,500 feet
  • Short-run and prototype options available
  • Standard lead times range from 3 to 8 weeks depending on complexity

Whether the project requires coaxial cores for signal control or sub-miniature wire for space-limited assemblies, Micro-Tek supports every step from initial design to full production.

Ready to build custom aerospace wire solutions? Contact Micro-Tek to discuss your requirements for custom aerospace wire manufacturing or request a quote for your next build.