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Product Overview
High-Performance Power and Data Cables, High-Performance Coaxial Cables & Aerospace Wire and Cable
High-Performance Power and Data Cables
MaxFlite data cables are high-performance, high- peed 100 Base-T Ethernet cables designed for use in aircraft IFE (In-Flight Entertainment) systems.They are also ideal for other applications using IEEE 1394, ARINC 629, and similar protocols. These cables feature our advanced LTE extruded expanded PTFE dielectric for increased velocity of propagation. They can also be used as components in more complex cables with additional components such as power wires, coaxial cables, or other types. MaxFlite cables meet the requirements of FAR 25.853/ Appendix F, Part 1 (a)(3) for burn/smoke test.
MaxFlite data cables are high-performance, high- peed 100 Base-T Ethernet cables designed for use in aircraft IFE (In-Flight Entertainment) systems.They are also ideal for other applications using IEEE 1394, ARINC 629, and similar protocols. These cables feature our advanced LTE extruded expanded PTFE dielectric for increased velocity of propagation. They can also be used as components in more complex cables with additional components such as power wires, coaxial cables, or other types. MaxFlite cables meet the requirements of FAR 25.853/ Appendix F, Part 1 (a)(3) for burn/smoke test.
As commercial aircraft entertainment systems become increasingly sophisticated, the technology of the cables used in the systems is an important factor in clean signal delivery. Thermax aircraft entertainment system cables are custom designs that are composed of materials that best suit not only the electrical and electronic characteristics of the specific system, but meet safety and reliability requirements as well. These cables typically include coaxial and/or high-speed twisted-pair twinaxial data cables, along with other component wires for power and signal transmission. The data-transmission cable components can also be supplied with our unique LTE expanded PTFE dielectric for increased data speed and light weight.
Thermax Low-Noise cables minimize triboelectric noise generated by cable movement, as well as providing superior shielding to protect signals from external interference. These cables are ideal for use with piezoelectric accelerometers or other sensitive transducers, or other applications with low-power signals and/or electrically noisy environments. They are also used in airborne EVM (Engine Vibration Monitoring) systems, with approvals from many major aerospace manufacturers. The cables shown below are just a few examples of our low-noise cable expertise. Many other combinations of materials and construction can be used to produce a low-noise cable that will fulfill your needs.
Thermax sensor cables are designed to maintain critical low-level signals from sophisticated sensors, providing a clean data transmission that helps preserve the information from the sensor. Whether your application calls for the measurement of weight, fluid levels, flow rate, proximity or vibration,we can design and build a cable to meet even your most demanding needs in such applications as:
- Pressure Transducers (Liquid Level, Flow Level, Load Cell);
- Photoelectric Transducers;
- Proximity Transducers;
- Vibration Sensors. We have extensive experience manufacturing rugged cable constructions suitable for hostile environments such as those present in wastewater treatment facilities, municipal drainage sumps, and ...
Almost any wire or cable in this catalog can be supplied as a Flight Test cable, with industry- standard orange jacket for identification. As a leader in aerospace wire and cable, we can apply our technical and manufacturing expertise to your most demanding applications especially in severe environments and high temperatures. Our low-noise designs are especially suited to flight test applications. Besides providing excellent shielding, the design of these cables minimizes triboelectric noise produced by cable movement. Our expertise in sensor cable design helps ensure that sensor data is transmitted cleanly to monitoring or recording equipment. Flight test cables can be supplied with our unique LTE expanded PTFE dielectric for increased ...
The new SAE AS5419 standard replaces the cancelled MIL-W-5846 specification. This standard defines thermocouple cables with a variety of insulation, shielding, and jacket materials
When your high-end speaker or interconnect cable requirements call for the latest high-performance materials,Thermax/CDT should be your first choice. Our experience in commercial aircraft cabin communications and in-flight entertainment systems means we have the knowledge to design audio cables that deliver clean, clear signals. We can apply our technical and manufacturing expertise to your most demanding applications. Put our expertise to work for you in the design of audio cables that provide controlled or optimized impedance and capacitance. We also offer constructions with reduced inductance in order to minimize signal loss, thereby maintaining signal integrity even over long cable runs. Our low-noise designs are especially suited to ...
High-Performance Coaxial Cables
LTE is a patented low-density, air-expanded PTFE dielectric which provides reduced weight and increased velocity of propagation (up to 85%). LTE dielectric also exhibits low loss and stable performance throughout its temperature range. These cables are ideal replacements for MIL-C-17 cables in demanding applications such as aerospace and high-reliability commercial systems.
- 875-892 is a replacement for RG-179 (M17/94).
- 900-142 is a replacement for RG-142 (M17/60,/158).
- 900-316 is a replacement for RG-316 (M17/113, /172).
- 900-393 is a replacement for RG-393 (M17/127, /174).
LTE low-density, air-expanded PTFE dielectric gives these cables very fast transmission speeds and low loss in a small size, along with exceptional flexibility. These cables are just some examples of the performance levels provided by LTE dielectric— many other configurations are also available.
LTE low-density, air-expanded PTFE dielectric gives these cables very fast transmission speed and low loss in a small size, along with exceptional flexibility. This cable is just one example of the performance levels provided by LTE dielectric- many other configurations are also available.
MaxForm cable is a hand-formable alternative to semi-rigid cable. With its 100% shield coverage, it provides equivalent performance to MIL-C-17 semi- rigid, but can be formed by hand without the use of bending equipment. Cable assemblies can be made to approximate overall length and bent to fit when installing into equipment. MaxForm cable can be used with connectors designed for MIL-C-17 semi-rigid cable, with no change in assembly procedures.
MaxFlex cable is a flexible alternative to semi-rigid cable. With its 100% shield coverage, it provides equivalent performance to MIL-C-17 semi-rigid, but is as flexible as many MIL-C-17 flexible coaxial cables. Using MaxFlex cable, assemblies can be made to approximate overall length and installed into equipment without the tooling required for bending semi-rigid cable.
(Mobile Solutions cable is low-loss, high-performance alternative to MIL-C-17 coaxial cables. The extruded, expanded PTFE dielectric (solid PTFE for MS-100) gives Mobile Solutions cables enhanced power-handling capability, low loss, and consistent performance throughout its temperature range. MS-195 cable can be used with connectors designed for RG-142 cable; MS-400 cable can be used with connectors designed for RG-213 cable.
MS2 is low-loss, high-temperature cable with superior electrical and environmental performance for the most demanding aerospace, wireless, and microwave applications. The air-spaced PTFE dielectric provides low loss and saves weight, and the sophisticated double shielding virtually eliminates crosstalk.This dielectric construction, and the extruded FEP jacket, ensure consistent performance throughout MS2's extended temperature range.
Thermax/CDT Mil-C-17 cables are constructed with either solid or stranded silver plated conductors insulated with an extruded PTFE (polytetrafluoroethylene) dielectric. The outstanding electrical and mechanical properties of PTFE over a broad range of temperatures and frequencies make these Thermax/CDT coaxial cables the standard for a wide range of military and commercial applications.
Aerospace Wire and Cable
MIL-W-16878 (NEMA HP3, HP4) wires
MIL-W-16878/4 (type E) wires have extruded PTFE insulation (medium wall thickness) for high- temperature applications. PTFE insulation offers high reliability with excellent thermal stability and chemical resistance.
MIL-W-16878/5 (type EE) wires have extruded PTFE insulation (heavy wall thickness) for high- temperature applications. PTFE insulation offers high reliability with excellent thermal stability and chemical resistance.
MIL-W-16878/6 (type ET) wires have extruded PTFE insulation (thin wall thickness) for high-temperature applications and light weight. PTFE insulation offers high reliability with excellent thermal stability and chemical resistance.
MIL-W-16878/11 (type K) equivalent wires have extruded FEP insulation (medium wall thickness) for high-temperature applications.These wires have tin- plated copper conductors for economy.
MIL-W-16878/12 (type KK) equivalent wires have extruded FEP insulation (heavy wall thickness) for high-temperature applications.These wires have tin- plated copper conductors for economy.
MIL-W-16878/13 (type KT) equivalent wires have extruded FEP insulation (thin wall thickness) for high-temperature applications.These wires have tin- plated copper conductors for economy.
Type E, EE and ET cables
Type E cables are shielded and jacketed cables with extruded FEP or PTFE tape jackets, incorporating MIL-W-16878/4 wires
Type EE cables are shielded and jacketed cables with extruded FEP or PTFE tape jackets, incorporating MIL-W-16878/5 wires
Type ET cables are shielded and jacketed cables with extruded FEP or PTFE tape jackets, incorporating MIL-W-16878/4 wires.
M22759 (SAE AS22759) wires
MIL-W-22759/5 wires have mineral-filled PTFE insulation for high-temperature applications such as aircraft engines, SWAMP zones, and others where increased abrasion resistance is required. For reduced-weight versions of these wires, see M22759/7 and /8
MIL-W-22759/6 wires have mineral-filled PTFE insulation for high-temperature applications such as aircraft engines, SWAMP zones, and others where increased abrasion resistance is required. For reduced-weight versions of these wires, see M22759/7 and /8
MIL-W-22759/7 wires have reduced weight, mineral-filled PTFE insulation for high-temperature applications such as aircraft engines, SWAMP zones, and others where increased abrasion resistance is required.These wires are reduced-weight versions of MIL-W-22759/5 and /6.
MIL-W-22759/8 wires have reduced weight, mineral-filled PTFE insulation for high-temperature applications such as aircraft engines, SWAMP zones, and others where increased abrasion resistance is required.These wires are reduced-weight versions of MIL-W-22759/5 and /6.
MIL-W-22759/9 wires have extruded PTFE insulation for high-temperature applications where the additional abrasion resistance of mineral-filled PTFE insulation is not required.These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. For versions of these wires with thinner-wall insulation and 600V voltage rating, see M22759/11 and /12.
MIL-W-22759/10 wires have extruded PTFE insulation for high-temperature applications where the additional abrasion resistance of mineral-filled PTFE insulation is not required.These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. For versions of these wires with thinner-wall insulation and 600V voltage rating, see M22759/11 and /12.
MIL-W-22759/11 wires have extruded PTFE isulation for high-temperature applications where the additional abrasion resistance of mineral-filled PTFE insulation is not required.These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. These wires are similar to MIL-W-22759/9 and /10 wires, but have a thinner-wall insulation and 600V voltage rating.
MIL-W-22759/12 wires have extruded PTFE isulation for high-temperature applications where the additional abrasion resistance of mineral-filled PTFE insulation is not required.These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. These wires are similar to MIL-W-22759/9 and /10 wires, but have a thinner-wall insulation and 600V voltage rating.
MIL-W-22759/16 wires have extruded ETFE insulation for aerospace and other applications requiring light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals. For versions of these wires with thinner-wall insulation for light weight, see M22759/18 and /19
MIL-W-22759/17 wires have extruded ETFE insulation for aerospace and other applications requiring light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals. For versions of these wires with thinner-wall insulation for light weight, see M22759/18 and /19
MIL-W-22759/18 wires have thin-wall extruded ETFE insulation for aerospace and other applications requiring light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.
MIL-W-22759/19 wires have thin-wall extruded ETFE insulation for aerospace and other applications requiring light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.
MIL-W-22759/20 wires have extruded PTFE insulation and a high-strength copper alloy conductor for greater break strength.They are ideal for aerospace and other applications requiring high reliability and break strength, enhanced flex life, and resistance to high temperatures. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. For versions of these wires with thinner-wall insulation and 600V voltage rating, see M22759/22 and /23
MIL-W-22759/21 wires have extruded PTFE insulation and a high-strength copper alloy conductor for greater break strength.They are ideal for aerospace and other applications requiring high reliability and break strength, enhanced flex life, and resistance to high temperatures. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. For versions of these wires with thinner-wall insulation and 600V voltage rating, see M22759/22 and /23
MIL-W-22759/22 wires have thin-wall extruded PTFE insulation and a high-strength copper alloy conductor for greater break strength. They are ideal for aerospace and other applications requiring high reliability and break strength, enhanced flex life, and resistance to high temperatures. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns.
MIL-W-22759/23 wires have thin-wall extruded PTFE insulation and a high-strength copper alloy conductor for greater break strength. They are ideal for aerospace and other applications requiring high reliability and break strength, enhanced flex life, and resistance to high temperatures. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns.
MIL-W-22759/28 wires have extruded PTFE insulation with a polyimide hard coat for increased cut-through and abrasion resistance. These wires are designed for aerospace and other applications requiring excellent thermal stability, tight dimensional tolerances, and high reliability. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. For versions of these wires with high-strength copper alloy conductor, see M22759/30 and /31.
MIL-W-22759/29 wires have extruded PTFE insulation with a polyimide hard coat for increased cut-through and abrasion resistance. These wires are designed for aerospace and other applications requiring excellent thermal stability, tight dimensional tolerances, and high reliability. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns. For versions of these wires with high-strength copper alloy conductor, see M22759/30 and /31
MIL-DTL-22759/30 wires have extruded PTFE insulation with a polyimide hard coat for increased cut-through and abrasion resistance, and a high-strength copper alloy conductor for greater break strength. These wires are designed for aerospace and other applications requiring excellent thermal stability, tight dimensional tolerances, and high reliability. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are a major concern
MIL-DTL-22759/31 wires have extruded PTFE insulation with a polyimide hard coat for increased cut-through and abrasion resistance, and a high-strength copper alloy conductor for greater break strength. These wires are designed for aerospace and other applications requiring excellent thermal stability, tight dimensional tolerances, and high reliability. These wires are especially well-suited in applications where smoke emission, overload stability, and flammability are major concerns.
MIL-DTL-22759/80 wires are light- weight, high-performance aerospace hookup wires with a dual-layer insulation of PTFE/polyimide/PTFE tape, covered with PTFE tape. These wires are designed for aerospace and other applications requiring excellent thermal stability, light weight, and high break strength. These wires are available with our unique Seamless Wrap PTFE tape insulation
MIL-DTL-22759/81 wires are light- weight, high-performance aerospace hookup wires with a dual-layer insulation of PTFE/polyimide/PTFE tape, covered with PTFE tape. These wires are designed for aerospace and other applications requiring excellent thermal stability, light weight, and high break strength. These wires are available with our unique Seamless Wrap PTFE tape insulation
MIL-DTL-22759/82 wires are light- weight, high-performance aerospace hookup wires with a dual-layer insulation of PTFE/polyimide/PTFE tape, covered with PTFE tape. These wires are designed for aerospace and other applications requiring excellent thermal stability, light weight, and high break strength. These wires are available with our unique Seamless Wrap PTFE tape insulation
MIL-DTL-22759/83 wires are large size, high-performance aerospace hookup wires with a four-layer insulation of PTFE tape and PTFE/ polyimide/PTFE tape, with an outer layer of polyamide braid for superior abrasion resistance. These wires are designed for aerospace and other applications requiring excellent thermal stability and abrasion resistance.
MIL-DTL-22759/84 wires are large size, high-performance aerospace hookup wires with a four-layer insulation of PTFE tape and PTFE/ polyimide/PTFE tape, with an outer layer of polyamide braid for superior abrasion resistance. These wires are designed for aerospace and other applications requiring excellent thermal stability and abrasion resistance.
MIL-DTL-22759/85 wires are large size, high-performance aerospace hookup wires with a four-layer insulation of PTFE tape and PTFE/ polyimide/PTFE tape, with an outer layer of polyamide braid for superior abrasion resistance. These wires are designed for aerospace and other applications requiring excellent thermal stability and abrasion resistance.
MIL-DTL-22759/86 wires are normal-weight, high- performance aerospace hookup wires with insulation composed of PTFE/polyimide/PTFE tape and PTFE tape in several configurations. These wires are designed for aerospace and other applications requiring excellent thermal stability and good abrasion resistance.
MIL-DTL-22759/87 wires are normal-weight, high- performance aerospace hookup wires with insulation composed of PTFE/polyimide/PTFE tape and PTFE tape in several configurations
MIL-DTL-22759/88 wires are normal-weight, high- performance aerospace hookup wires with insulation composed of PTFE/polyimide/PTFE tape and PTFE tape in several configurations. These wires are designed for aerospace and other applications requiring excellent thermal stability and good abrasion resistance.
MIL-DTL-22759/89 wires are light-weight, high-performance aerospace hookup wires with a dual-layer insulation of PTFE/polyimide/PTFE tape, covered with PTFE tape.They are similar to MIL-DTL-22759/81 and /82 wires, but have thicker-wall insulation. These wires are designed for aerospace and other applications requiring excellent thermal stability and high break strength.
MIL-DTL-22759/90 wires are light-weight, high-performance aerospace hookup wires with a dual-layer insulation of PTFE/polyimide/PTFE tape, covered with PTFE tape.They are similar to MIL-DTL-22759/81 and /82 wires, but have thicker-wall insulation. These wires are designed for aerospace and other applications requiring excellent thermal stability and high break strength.
MIL-DTL-22759/91 wires are light-weight, high-performance aerospace hookup wires with a dual-layer insulation of PTFE/polyimide/PTFE tape, covered with PTFE tape. These wires are designed for aerospace and other applications requiring excellent thermal stability and lightweight.
MIL-DTL-22759/91 wires are light-weight, high-performance aerospace hookup wires with a dual-layer insulation of PTFE/polyimide/PTFE tape, covered with PTFE tape. These wires are designed for aerospace and other applications requiring excellent thermal stability and lightweight.
MIL-W-25038 wires
These wires are designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration and with direct flame exposure. This heavy-duty, non-asbestos construction offers excellent mechanical performance and abrasion resistance.
Thermazone IIIK wires are designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure. Thermazone IIIG wires also meet or exceed the requirements of MIL-W-25083/3, but provides this performance at a lower cost through the use of an innovative insulation system.
Thermazone IIIK wires are designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure. Thermazone IIIG wires also meet or exceed the requirements of MIL-W-25083/3, but provides this performance at a lower cost through the use of an innovative insulation system.
MIL-DTL-27500 (NEMA WC27500) cables
Shielded and jacketed cables with PTFE tape or extruded PFA jackets, incorporating MIL-W-22759/7 or /8 wires. These component wires are insulated with light-weight mineral filled PTFE and have silver-plated or nickel-plated conductors. Versions with PTFE tape jackets are available with Seamless Wrap PTFE tape.
Shielded and jacketed cables with PTFE tape or extruded PFA jackets, incorporating MIL-W-22759/7 or /8 wires. These component wires are insulated with light-weight mineral filled PTFE and have silver-plated or nickel-plated conductors. Versions with PTFE tape jackets are available with Seamless Wrap PTFE tape.
Shielded and jacketed cables with PTFE tape or extruded FEP jackets, incorporating MIL-W-22759/11 or /12 wires. These component wires have extruded PTFE insulation and silver-or nickel-plated copper conductors. PTFE tape jackets are available with Seamless Wrap PTFE tape.
Shielded and jacketed cables with PTFE tape or extruded FEP jackets, incorporating MIL-W-22759/11 or /12 wires. These component wires have extruded PTFE insulation and silver-or nickel-plated copper conductors. PTFE tape jackets are available with Seamless Wrap PTFE tape.
Shielded and jacketed cables with extruded ETFE (Ethylene Tetrafluoroethylene) jackets incorporating MIL-W-22759/16 or /17 wires. These component wires are insulated with extruded ETFE and have either tin-plated copper or silver-plated high-strength copper alloy conductors
Shielded and jacketed cables with extruded ETFE (Ethylene Tetrafluoroethylene) jackets incorporating MIL-W-22759/16 or /17 wires. These component wires are insulated with extruded ETFE and have either tin-plated copper or silver-plated high-strength copper alloy conductors.
Shielded and jacketed cables with extruded ETFE (Ethylene Tetrafluoroethylene) jackets incorporating MIL-W-22759/16 or /17 wires. These components wire are insulated with thin-wall extruded ETFE for weight and space savings and have either tin-plated copper or silver-plated high-strength copper alloy conductors.
Shielded and jacketed cables with extruded ETFE (Ethylene Tetrafluoroethylene) jackets incorporating MIL-W-22759/16 or /17 wires. These components wire are insulated with thin-wall extruded ETFE for weight and space savings and have either tin-plated copper or silver-plated high-strength copper alloy conductors.

