Aerospace Wire Solutions for the Defense Industry

Consistent performance for varied and demanding environments

MWS Wire / Aerospace Wire – Defense Industry

MWS Wire is the Leader in Aerospace Wire Manufacturing

MWS provides the defense industry with ITAR compliant aerospace wire solutions that deliver as required. Our performance on the forefront of new technologies demonstrates our ability to tackle any defense 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.

Aerospace and Mil-Spec wire.

We provide aerospace wire solutions to support the latest technologies whether its rectangular wire for magnetic bearings or space efficient electric motors for unmanned arial systems.  We also provide wire for motor rewinds supporting MRO activities and re-engineering of legacy systems 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 Defense.

Motor Windings for Motion Control Units in Guided Arial Systems

Reusable or single-use guided aerial systems require precise controls. There are many physical demands on motion control units. A motion control motor must be contained in a small envelope yet have enough power to last until the mission is complete. The motor winding configuration must be robust enough to endure all the shocks and vibrations caused by rocket flight. The insulation must be heat tolerant and stay in peak condition during long storage cycles.

We work with our partners in the defense industry providing them with the best wire so that they can in turn support our warfighters and allies.

Unmanned Autonomous Vehicles

In advanced military Unmanned Autonomous Vehicle and drone platforms, every gram and cubic millimeter counts. Our specialty motor and actuator wire enables a new level of power density and control authority. Microsquare Magnet Wire® and other precision-shaped conductor geometries allow us to pack more copper into less space, delivering denser windings that translate directly into higher torque and power from smaller motors. The tightly controlled shape and dimensions improve fill factor, reduce heat, and increase electromagnetic performance, allowing smaller motor envelopes without sacrificing thrust, endurance, or responsiveness. Combined with high-temperature, chemical resistant insulation systems qualified for harsh environments and high vibration duty cycles, our wire technology gives defense programs a practical way to increase payload capability and mission range while preserving the compact form factors critical to ISR and strike class UAV systems.

Wire for Power Generators and Inductor Coils

For military aircraft platforms where engine driven AC generators and induction coils are critical for maintaining avionics, flight controls and weapons systems, our precision magnet wire and coil winding solutions ensure unmatched reliability and performance under extreme operational demands. With custom geometries for optimal slot fill and superior dielectric strength, while meeting applicable specifications and traceability, we empower OEMs and MROs to extend generator life, minimize failures, and sustain combat readiness in the most demanding fixed wing and rotorcraft platforms.

Towed Decoy Systems

Towed decoy systems, used in a variety of military aircraft worldwide, consist of expendable or reusable countermeasures deployed from the aircraft itself as a response to threats. When activated, a thin towline unreels behind the host aircraft to position a countermeasure device that  lures air-to-air or surface-to-air missiles away from the real target.  Critical to towed decoy systems is of course the tether that keeps the countermeasures at a safe and effective distance from the aircraft.  That cable not only needs to survive high speeds and high G maneuvers, but also effectively transmit data. This is no small feat, even with high strength and ultra lightweight wire.

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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