AS22759 Aerospace Wire

Engineered for absolute reliability under extreme conditions, Frigate’s AS22759 aerospace wires deliver high-performance signal and power transmission for critical military and commercial aviation systems. Featuring advanced fluoropolymer insulation (PTFE/ETFE), these lightweight, high-temperature wires resist severe thermal cycling, chemical exposure, and mechanical abrasion.

Conductor Material

Silver-plated copper, nickel-plated copper, or high-strength copper alloy

Insulation Type

Extruded PTFE, ETFE, or cross-linked ETFE (XL-ETFE)

Voltage Rating

600V RMS (standard for aerospace power and signal distribution)

Temperature Range

-55C to +200C (dependent on specific dash number and plating)

Conductor Gauge Range

4/0 AWG down to 32 AWG

*Note: Listed schedules are indicative ranges based on standard material availability. Exact fulfillment timelines depend on specific AWG sizes, plating choices, and current global raw-material lead times at order finalization.

Product Description

Frigate’s AS22759 aerospace wire series is manufactured to strict military standards (MIL-SPEC), ensuring flawless performance across demanding defense, aerospace, and high-performance industrial environments. Its cross-linked or extruded insulation options provide an exceptional strength-to-weight ratio, allowing engineers to optimize weight savings without compromising electrical or structural integrity.

Flammability Rating

Self-extinguishing, resistant to open flame and thermal propagation

Chemical Resistance

Immune to aviation fuels, hydraulic fluids, lubricants, and solvents

Dielectric Strength

High dielectric performance with minimal signal attenuation or leakage

Mechanical Durability

Exceptional resistance to scraping, cut-through, and structural abrasion

Smoke/Toxicity Profile

Low-smoke emission and minimal toxic gas release under thermal stress

Flexibility Class

Optimized stranded configuration for tight-bend radii in airframe harnesses

Applicable Standards

SAE AS22759, formerly MIL-W-22759 specification compliant

Outgassing Properties

Low outgassing characteristics, suitable for vacuum and space environments

Environmental Stability

Hydrolysis-resistant and UV/Ozone stabilized for prolonged exposure

Color Availability

Compliant with MIL-STD-104; available in standard solid colors and stripes

Technical Advantages

By utilizing high-grade conductors including silver-plated, nickel-plated, or tin-plated copper and copper alloys, our AS22759 wires maintain excellent conductivity and oxidation resistance at continuous temperatures up to 200°C. Additionally, the specialized insulation offers superior resistance to fluid immersion, arc tracking, and flame propagation, meeting the stringent safety regulations of modern aerospace engineering.

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Industry Applications

Airframe Environmental Control Systems

Engineered to route power through wings and fuselage zones exposed to severe hydraulic fluids, fluctuating pressure, and harsh structural vibrations.

Avionics & Flight Deck Instrumentation

Delivers EMI-shielded, low-loss signal propagation for flight control computers, navigation displays, and mission-critical communication suites.

Military UAVs & Defense Systems

Optimized lightweight wiring that minimizes overall payload weight, maximizing flight endurance and operational range for unmanned aerial platforms.

Space Launch Vehicles & Satellites

Meets strict vacuum and low-outgassing parameters required to maintain electrical integrity in low-Earth orbit and deep-space deployments.

Engine Nacelles & APU Wiring

Sustains continuous operational reliability in close proximity to high-temperature engine zones, resisting thermal degradation up to 200°C.

High-Performance Marine & Motorsport

Deployed in high-end racing wire harnesses and marine command consoles requiring maximum protection against salt spray, oil, and heavy impacts.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

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Defence-Grade Cable Supply

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Flange Assembly for Pump

Faster Production

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Having Doubts? Our FAQ

Can Frigate provide full material traceability and CoC (Certificate of Conformance) for custom AS22759 orders?

Yes. Every batch of AS22759 wire supplied by Frigate undergoes rigorous quality control and comes complete with full material traceability, physical testing reports, and a formal Certificate of Conformance aligning with aerospace standard certifications.

We require a specific dash number (e.g., /11, /16, /34) for our defense contract. Can you manufacture to exact slant sheets?

Absolutely. Frigate manufacture custom runs according to specific SAE AS22759 slash sheets, ensuring you get the exact conductor plating (silver, nickel, or tin) and insulation chemistry (PTFE, ETFE, or dual-wall XL-ETFE) your design blueprint mandates.

What are Frigate's capabilities regarding custom color coding, striping, or surface laser marking for complex harness assemblies?

To streamline your wire harness production, we offer custom spiral striping, solid color-coding compliant with MIL-STD-104, and surface prep optimized for UV laser marking systems so your assembly technicians can easily identify lines.

How does Frigate handle MOQ (Minimum Order Quantity) for specialized gauge sizes or high-strength copper alloy variants?

While standard copper core lines have flexible MOQs, specialized high-strength copper alloy cores or ultra-fine gauges (28–32 AWG) may carry minimum run requirements based on raw material casting sizes. Contact our engineering desk to discuss your specific program needs.

Can we establish a blanket order agreement with scheduled releases to mitigate lead time fluctuations for our multi-year production cycle?

Yes, we frequently establish annual contract agreements. We hold buffer stock in our warehouse based on your forecast, guaranteeing 48-hour Just-In-Time (JIT) dispatch and locked-in pricing against market volatility.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Components Built for Critical Performance

Engineered Products for Critical Applications

AS22759 Aerospace Wire

Product Description

Flammability Rating

Chemical Resistance

Dielectric Strength

Mechanical Durability

Smoke/Toxicity Profile

Flexibility Class

Applicable Standards

Outgassing Properties

Environmental Stability

Color Availability

Technical Advantages

Let's Get Started

Industry Applications

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

AS22759 Aerospace Wire

Get Latest Price

AS22759 Aerospace Wire

Get Latest Price