Aerospace Connectivity Solution
Application type: Aerospace Systems Integrator
Engineering Note
This application note explains the material selection and validation route. Actual projects should be confirmed against drawings, standards, process windows, sample testing and commercial availability.
Application Fit
Confirm whether the material system fits the service condition before comparing only by price or material name.
Validation Route
Sample validation should cover dimensions, conductivity, bonding, surface condition, joining process and environmental reliability.
RFQ Fields
Provide drawing, specification, tolerance, application, annual demand, packaging and inspection document requirements together.
The Challenge
Develop lightweight, high-performance conductors for aircraft communication and power systems
Review Route
Custom-designed high-strength CCA conductors optimized for weight and performance
Procurement Value
22% weight reduction, $50K annual fuel savings per aircraft, FAA flammability certified
Project Timeline
Engineering
Custom 6000-series Al core with 15% Cu cladding
Certification
Passed FAA flammability & smoke density tests
Fleet Rollout
Estimated $50K/year fuel savings per aircraft
Background
Commercial aircraft contain hundreds of kilometers of wiring, contributing 2–5% of total aircraft weight. For a mid-range widebody, that can exceed 2,000 kg — a significant fuel cost driver over a 20-year service life. An Aerospace Systems Integrator responsible for next-generation airframe electrical architecture sought bimetallic conductors that could slash weight without compromising safety certifications or electrical performance.
The Challenge
The airframe program required conductors that would:
- Reduce wiring system weight by at least 20% compared to conventional copper
- Pass FAA flammability and smoke density testing (14 CFR Part 25) for in-cabin installations
- Maintain equivalent ampacity and voltage drop performance for power distribution circuits
- Meet aerospace quality management system requirements for supply chain traceability
The Solution: Raytron High-Strength CCA Aerospace Wire
We supplied our high-strength CCA wire with aerospace-grade specifications:
- Construction: 6000-series aluminum core with 15% copper volume cladding — high strength-to-weight ratio with a fully copper-compatible outer surface
- Flammability: Passed FAA 14 CFR Part 25 flammability and smoke density tests — self-extinguishing, low smoke emission
- Ampacity: Matched copper-equivalent current ratings through optimized cross-section design, maintaining voltage drop within specification
- Quality assurance: Produced under ISO 9001-certified quality management system with full material traceability from billet to finished wire
Results
- Weight Savings: 22% reduction in total wiring system weight compared to copper reference design
- Fuel Economics: Estimated $50,000 per aircraft per year in fuel cost savings from weight reduction
- Certification: Passed FAA flammability and smoke density testing; ISO 9001 quality system certified
- Performance: Ampacity and voltage drop performance matched copper-equivalent specifications across all circuit classes
Need a Similar Engineering Review?
Send the drawing, application and target specification so Raytron can help review material routes, validation priorities and RFQ fields.