Mil-Spec Wire

Types of Mil-Spec Wire

Mil-spec wires are categorized by the military specification standards that outline the requirement and testing procedures for each wire. Some common specifications include:

MIL-W-16878: Covers various types of unshielded wire for hook-up and lead wiring of electrical equipment and electronic components. M16878 is commonly used in aerospace aircraft wing wiring systems, communications systems, and industrial machinery.

MIL-W-22759: Covers high-performance wire commonly used in aerospace applications where high temperature resistance, low weight, and low flame propagation are important considerations. In addition to military and aerospace applications, M22759 is also employed in spacecrafts and satellites, high-performance automotive wiring, and marine environments.

MIL-W-81044: Covers cross-linked ETFE insulated wire for high temperatures. Also offers low weight resistance to chemicals, abrasion, and shrink back. M81044 wire is also used in military vehicles and airframe applications where high-density cabling and harnessing are required.

MIL-W-81381: Covers polyimide-insulated single conductor wires. Offers excellent cut-through and abrasion resistance. M81381 is lightweight, highly reliable, and offers excellent thermal stability up to 200 degrees Celsius.

MIL-DTL-27500: Covers single or multi-conductor wire. Often employed in military and aerospace applications, M27500 cable performs under extreme conditions and environments.

The materials vary depending on the specific environmental conditions, electrical needs, and physical demands of the application. Consult the chart on the product page for conductor, voltage, temperature rating, and insulation information.

We’ve Got You Covered: Shields, Jackets, and Insulations

Shields, jackets, and insulations play distinct roles in protecting and ensuring the functionality of electrical wire. Understanding the differences between these components helps in selecting the right wire or cable for specific applications, ensuring it meets the necessary performance and durability requirements.

Shields

Shielding protects wire from external electromagnetic interference (EMI) and prevents the wire’s own electromagnetic emissions from interfering with nearby electronic equipment. Shielding is usually made from conductive materials like aluminum or copper (sometimes both) in the form of braids and/or foils.

Jackets

The jacket is the outer layer of a wire or cable that protects the internal components from physical damage by moisture, chemicals, UV radiation, or other environmental factors. Common jacket materials include Polyvinyl Chloride (PVC), Polyethylene (PE), Thermoplastic Elastomer (TPE), and Neoprene.

Insulation

Insulation prevents an electrical current from escaping the conductor and protects the wire from environmental factors. Our mil-spec inventory includes the most common industry insulators including Polyvinyl Chloride (PVC), Teflon (PTFE), Crosslinked Modified ETFE, Fluorinated Ethylene Propylene (FEP), and Extruded TFE materials.

The type of insulation used on your mil-spec wire or cable affects the wire's temperature rating, flexibility, chemical resistance, and durability. Here are a few key differences between them:

PVC	Used for more general-purpose applications where extreme environmental conditions are not a factor.
PTFE and ETFE	Offer high-temperature and chemical resistance properties, so they are commonly used in applications where they will be exposed to extreme heat and/or chemicals.
FEP	Used in wiring systems that require high performance in extreme temperatures, high altitudes, or when exposed to harsh chemicals.

Contact Us

Not sure which mil-spec wire or cable you need for your application? Want to learn more about our value-added custom cable design services? Request a quote or give us a call at (860) 589-0055.