Aerospace Wire Solutions for Commercial Aircraft

Consistent performance for varied and demanding environments

MWS Wire / Aerospace Wire – Commercial Aircraft

MWS Wire is the Leader in Aerospace Wire Manufacturing

Aerospace industries have long turned to MWS Wire for custom wire solutions that can deliver the expected performance in a variety of demanding conditions. Our performance on the forefront of new aerospace technologies demonstrates our ability to tackle any aerospace customer need. Whether it's exotic or routine, it needs to be simple and reliable.

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Core MWS Technologies for Aerospace Wire

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Product Spotlight

Polyimide ML

Polyimide ML is a durable high-temperature (thermal class 240°C) heat resistant insulation offering protection from external and internal heat sources and allowing wire products to withstand bakeout temperatures. This insulation is frequently used in high-temperature continuous duty coils, hermetically sealed relays, and fractional and integral HP motors.

Because of its thermal insulation and radiation resistance properties, Polyimide (ML) is used to wind coils on satellites, spacecraft and launch vehicles. Other uses include avionics, navigation, flight controls, wing movement, and collision avoidance.

Electronic applications – Polyimide (ML) film is ideal for high heat environments, such as wheel speed sensors, brake control systems and for the majority of applications in all Aerospace market segments.

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Technology Focus

Heat Resistant Polyimide Insulation

This resin not only has excellent heat stability, but also great mechanical and electrical characteristics and reliability, thus achieving a long history of use and popularity. These applications are continuously expanding to include use in insulated covers for heat-resistant wires, as well as parts used in airplane production and industrial equipment.

Top Features of the Polyimide ML Heat Membrane:

  • High strength and elasticity
  • Heat and cold resistance
  • Can be used at a wide range of temperatures: between -269°C and 400°C
  • High-voltage insulation properties
  • Chemical resistance / Oil resistance
  • Resistance to radiation
  • Dimensional stability
  • Nonflammable

Wire Insulations

The key to dielectric strength

Coating the bare conductor material with a non-conductive flexible insulation is at the heart of the MWS manufacturing process and gives the wire its dielectric strength. Depending on the application and performance characteristics, MWS offers a variety of polyester, polyurethane, and Polyimide insulations for different thermal classes and specific application needs.

Aviation Wire

Whether it’s stainless steel wire for tiedown applications, copper conductors for wire harnesses, or a complete MRO motor rewind,  MWS has the right conductors and the right high-performance insulations -  all made to the appropriate specifications to meet aviation material and traceability requirements.

Custom Square, Flat, and Ribbon Wire shapes

The key to compact and powerful motors

MWS has the manufacturing expertise and specialty equipment to create custom wire in niche shapes and aspect ratios such as square and rectangular wire including Microsquare® wire (15 gauge and finer),  Multifilar®, Twistite® and rectangular magnet wire for specialty coil and motor windings. Special shapes such as square and rectangular magnet wire can handle tighter dimensional specifications and create more compact coils and small motors that deliver more power in less space.

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Our Wire.
Applied for Commercial Aerospace.

Solenoids for Aviation Safety Devices

A RAT (Ram Air Turbine) is usually hidden inside the aircraft underbelly and will only be deployed in case of an engine failure. The RAT turbine turns from the remaining speed of the aircraft (airstream) and generates just enough power to keep critical systems working (which are usually powered by the main engines). These systems, like hydraulics and controls, are vital to be able to land an aircraft after engine loss.

Overall, RAT’s have saved as many as 1,700 lives across 16 documented incidents.

Stator Windings in eVTOL Aircraft

Electric Vertical Takeoff and Landing (eVTOL) aircraft are part of a new class of aviation made possible by advances in electric motor technology. Newer motors have greatly improved power-to-weight ratios making these vehicles not only possible but more energy efficient for tasks such as vertical take-off, hover, climb, and descent. Powerful high-torque motors require the right electromagnetic wiring in the stator portion of the motor. MWS specializes in copper alloy coil winding wire technology that produces compact coils and small motors delivering more power in less space.

With exciting applications in cargo delivery, airport taxi services, emergency response, or those "flying cars" we've been promised for years, the eVTOL industry is going to continue to make us feel that we are living in the future.

Fire Suppression Systems

Integrated fire detection and suppression systems consist of monitored wire loops where continuity or resistance is checked for any unexpected values. These wire-based sensor systems are critical to provide early-warning heat and smoke detection for cargo and engine compartments, APUs, and avionics areas. Since aircraft wiring in many areas are already exposed to high temperatures, fluids, and vibrations, specialty wire such as nickel based alloys and high temperature insulation like polyimide are used to keep these systems operating nominally.

Aftermarket Motor Rewinds

Motor rewinds extend the life of electric motors and generators in all commercial aircraft support systems like actuators, pumps, fans, starters and APUs.  For aerospace MROs and FAA-certified repair stations focused on aftermarket motor rewinds, we provide high strength copper magnet wire in rectangular, litz, or round enamel to match the original gauge, resistance and thermal class of legacy systems.

The MWS Manufacturing and Engineering Advantage

More than just wire, we offer a full engineering solution for new and MRO products

At the heart of MWS Wire Industries is our state-of-the-art 75,000 sq. ft. facility and offices, with 25,000 sq. ft. manufacturing space and 40,000 sq. ft. warehouse space. This allows us to support customers from product development through the qualification phases. We’ve assisted customers in replicating the environments their products will be used in to ensure our products comply to existing OEM specifications when it comes to wire products used for maintenance, repair, and overhaul. More than just wire, we offer a full technical data package and engineering support. Our testing capabilities include mechanical properties such as stress/strain analysis, electrical properties such as DC resistance and dielectric strength, and base metal chemical analysis accurate to 1 ppm.

Specialty Equipment

All our equipment has been tailored to our unique manufacturing capabilities. We can produce wire of different shapes, sizes, and insulations you won’t easily find at other wire manufacturers. We carry sizes ranging from .0571″ down to .0005” in round diameters and ribbon thickness as low as .001″ and widths as wide as .125.″ These sizes are produced in pure metal, alloy and plated conductors. Products can be supplied in all tempers, from dead soft annealed to spring. Our vertical ovens allow us to manufacture film insulated wire conforming to NEMA MW 1000 in temperature classes 105°C to 240°C, from single through quadruple film builds.

Unrivaled Availability, Low Minimum Order Quantity, and Quick Delivery

MWS has one of the largest inventories of stainless-steel wire and other wire products. We provide wire from 1/4lb to 50lb spools. Ninety percent of our stock orders go out within a week. Low MOQs, short production runs, and quick turnarounds are our specialty.

Pre-cut Wire Lengths and Other Custom Orders

We can provide straight wire cuts from one inch to 6-foot lengths holding the tolerances you require for your specific application. Need shaped wire? We have a variety of special shapes including square wire, flat wire, and ribbon wire. Special coatings and finishes are available as well.

Headache Free Compliance, FAIR, and QPL Documentation

Let us help you satisfy your customer’s needs for clear and comprehensive compliance documentation including RoHS, REACH, DFARS, MADE IN USA, USMCA, etc. We can provide first article reports and we are also on the Qualified Products Lists for many major aerospace manufacturers.

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Aerospace Wires Inventoried or Produced by MWS

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