Aerospace Connectivity Solution

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 AS9100 quality management system requirements for aerospace 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 AS9100-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; AS9100 quality system certified
• Performance: Ampacity and voltage drop performance matched copper-equivalent specifications across all circuit classes