Next-Generation Aerospace Connectivity: Amphenol CIT’s MIL-Spec & Fiber Optic Cable Solutions

Crafting Tomorrow's Connectivity and Data Transmision

As the aviation industry continues to evolve towards higher standards, companies like Amphenol CIT lead the way by providing advanced cable solutions that meet rigorous military and commercial specifications. Among the most widely distributed products from Amphenol CIT are the Seamless and Seamless-T™ MIL-Spec cables, ECS Brand Coax cables, and LITEflight™ Fiber Optic cables. Additionally, Amphenol CIT’s Gigabit, NETflight™, and Maxflight™ series cables offer modern solutions for high-speed data transmission and reliable connectivity.

MIL-Spec Cables: Seamless PTFE Wire Insulation & Cable Jacket Technology

Engineered to increase the performance concerns composite insulations, Amphenol CIT’s Seamless PTFE wire and cable jacket technologies offers all the advantages of a tape wrap, with the smooth appearance and installation characteristics of an extrusion. Designed for use in commercial and military aerospace applications, Amphenol CIT’s Seamless wrap PTFE wire meets all the requirements for AS22759/80-/92 and NEMA WC27500. Seamless-T™ meets the requirements of AS22759/180-/192 and NEMA WC27500.

Construction:

• MS27500: Cables feature one to fifteen AS22759, M25038, or MIL-DTL-81381 wires, plus a single or double shield and a single or double jacket.

• AS22759/80-/92: Hook-up Wires feature either dual-, three- or four-layer insulation constructions with copper alloy, tin-, silver-, or nickel-plated stranded conductors.

• AS22759/180-/192: Hook-up Wires feature either dual-, three- or four-layer insulation constructions with copper alloy, tin-, silver-, or nickel-plated stranded conductors.

Advantages:

1. Smaller Diameter: Seamless PTFE Wire Insulation requires 15% to 20% less cross-sectional area than an equivalent XLETFE wire bundle, economizing space and increasing routing density.
2. Abrasion Resistance: Seamless PTFE Wire Insulation provides much higher cut through resistance, especially in higher temperature applications.
3. Mechanical Toughness: Seamless PTFE Wire Insulation has no edges, lessening the likelihood of catching and the robust, tough surface is less likely to get scraped, scratched, or damaged during installation.
4. Excellent Temperature Performance: Offering extended temperature ranges when compared to XLETFE constructions with NPC configurations rated up to 260 °C. 

Applications:

• General purpose airframe wire.

• Power feeders.

• Signal low frequency.

• Avionics boxes.

• Hot zones / engine applications

Many Amphenol CIT M27500 cables can be ordered with component wires and an outer jacket layer featuring Seamless wrap PTFE tape insulation. Specifically, cables with type 24 and 25 (single) and type 74 and 75 (double) jackets and AS22759/80 through /92 and AS22759/180 though /192 component wires can be ordered with Amphenol CIT’s unique Seamless wrap.

LITEFlight® Fiber Optic Cables: High-Speed Data Transmission in Modern Aircrafts

As the demand for high-speed data transmission continues to grow within the aerospace sector, fiber optic cables have become an integral component of modern aircraft systems. Amphenol CIT’s LITEflight™ Fiber Optic Cables offer industry-leading performance and durability in the demanding conditions found in harsh environments.

The LITEflight™ family of products is specifically designed to provide all the performance and benefits necessary to perform in the harsh environments of aerospace and military applications with low loss, tight bend radius, improved thermal stability, and peak performance during termination and installation.

Construction:

• LITEflight™ EP is available in simplex, ruggedized simplex, ruggedized duplex, and ruggedized quad configurations.
• LITEflight™ HD offers a multi-channel fiber cable in the smallest package, compatible with industry leading MPO connector interfaces and emerging multi-fiber termination connectors.
• LITEflight™ HP features excellent thermal stability and ideal connector/contact compatibility in a semi-loose construction for challenging harsh environment installations.
• LITEflight™ TS offers the best-performing tight structured cable in the industry, featuring low loss and high bandwidth. Available in all standard multimode and single-mode core types.
• LITEflight™ POF is the only aerospace-qualified POF cable on the market today and offers the highest performing plastic optic cable for harsh environment installations.

Advantages:

1. Lightweight and Compact: No need for heavy, bulky shielding over cables/connectors and bundles can be routed along with power and other signals.
2. EMI Immunity: Cables can be routed right next to high interference sources, offering increased advantages within the more-electric and all-electric aircraft environment.
3. Durability: Suitable for tight routing and severe installation requirements.
4. Safety: Reduced risk of fire, electrocution, irradiation, and more. 

Applications:

• Control - Fly by Light System

• Subsystem Interconnect - Communication, Radar, FLIR, LIDAR, etc.

• Sensor - Positional/acuators, smart structures/health monitoring, Inertial monitoring, etc.

Amphenol CIT’s LITEflight™ Fiber Optic Cables are suitable for G-Force environments, corrosive and caustic installations scenarios, and high-temperature and high-vibration environments.

Amphenol CIT ECS Brand Coax Cables: Ensuring Signal Integrity in Critical Systems

In addition to fiber optic solutions, coax cables remain vital for certain applications within aircraft, especially in radio frequency (RF) and microwave signal transmission. They are designed to meet the specific demands of aerospace applications.  CIT’s wide variety of high-performance data cables are designed to meet the needs of aerospace and defense applications.

Available Constructions:

• 50 Ω Coaxial Cables: Manufactured with materials which, when subjected to flames or high temperatures, will not outgas deadly hydrogen chloride produced by conventional PVC cables.
• Triaxial & 75 Ω Coaxial Cables: Manufactured with materials which, when subjected to flames or high temperatures, will not outgas deadly hydrogen chloride produced by conventional PVC cables.
• ECS Lightning Series: Exceptionally lightweight, extremely low-loss, and high velocity 50 Ω RF cable solution with the innovative use of silver-plated copper-clad aluminum conductors and shields offering a unique combination of form, function, and performance that is unmatched in the market.

Advantages:

1. Half the diameter of RG Cables
2. Up to 75% lighter than MIL-C-17 standard cables
3. Small bend radio – increased flexibility for routing during installation
4. Meets or exceeds FAR Part 25 Burn/Smoke requirements
5. Superior protection from EMI/RFI interference

Versatility: Can be used for multiple applications, including navigation systems, communication equipment, and in-flight entertainment systems.

Amphenol CIT also has ECS Brand Avionics RF Connectors designed specifically for the ECS Brand Avionics Coax Cables to enhance the cables’ performance and ensure a quality end product. They are engineered to be rugged, seal out moisture, and hold up to environmental variations under high temperature and pressure.

Amphenol CIT High-Speed Digital Data Cables: Gigabit, NETflight™, & Maxflight™ Series

Amphenol CIT High-Speed Digital Data cables are designed to minimize weight and size, while maintaining data-transmission and signal integrity in harsh environment installations.

Available Constructions:

• Gigabit: Ethernet cables developed in a wide variety of configurations to provide 1 and 10 Gb performance in the most demanding applications.
• NETflight™: Ethernet cables in single pair, dual pair, and quadrax configurations are widely used throughout the aerospace industry and provide superior electrical and mechanical performance.
• Maxflite™: Cables provide high-speed performance for popular video and data bus protocols including, HDMI, DVI, USB, and Firewire.

Advantages:

1. Operating performance from -55 °C to as high as 200 °C
2. Advanced technologies, including bonded pairs and an innovative X-Web, reduce crosstalk and ensure installable performance
3. Lightweight versions to address weight and space requirements
4. Exceptional electrical and mechanical performance

To ensure customers can feel confident that they have the optimal high-speed data solution, Amphenol CIT offers several twisted pair 100ohm cables that are compatible with the Octax™ connector series.