MIL-DTL-27500 Shielded Cable Assemblies

Engineered for precision and built to withstand the harshest aerospace and defense environments, Frigate’s custom MIL-DTL-27500 cable assemblies deliver uncompromised signal integrity and rugged durability. We provide fully tailored, mission-critical interconnect solutions built precisely to your exact print, compliance mandates, and harsh-environment specifications.

Military Specification

Fully compliant with MIL-DTL-27500 standards (WC designations)

Conductor Sizes Range

Available from 0000 AWG down to 32 AWG for diverse power and signal needs

Primary Wire Components

Formulated with MIL-W-22759, MIL-W-16878, or custom specified inner conductors

Shielding Material Options

Tin-coated copper, silver-coated copper, nickel-coated copper, or high-strength alloys

Shielding Coverage

Minimum 85% optical coverage standard, with options up to 95% for high-EMI zones

*Note: These timelines are indicative ranges only; actual fulfillment depends on component availability, specific custom testing mandates, and engineering complexity.

Product Description

Frigate specializes in fabricating custom, build-to-print MIL-DTL-27500 shielded cable assemblies designed to protect sensitive data lines from severe electromagnetic interference and mechanical stress. Our advanced contract manufacturing facility manages everything from automated stripping and precision braiding to complex overmolding, delivering turnkey interconnect systems that seamlessly drop into your production line.

Jacket Extrusion Materials

Cross-linked PVDF, PTFE, FEP, Polyurethane, and low-smoke zero-halogen (LSZH)

Voltage Rating

Operating Temperature

Continuous performance spanning from -65° C up to +200° C (jacket dependent)

Dielectric Withstanding Voltage

Tested up to 2500V AC RMS to guarantee zero insulation breakdown

Insulation Resistance

Minimum 5000 Megohms-1000 ft at 20°C testing benchmarks

Connector Integration

Precision termination to D38999, MIL-DTL-83513, or specified rugged hardware

Backshell & Boot Matching

Overmolded or shrink-boot options with AS85049 environmental backshells

Environmental Sealing

IP67 or IP68 rated moisture-proofing and potted transitions available

Testing Protocols

100% continuity, insulation resistance, DWV, and automated cross-talk testing

Compliance & Traceability

AS9100D certified manufacturing, full material certs, and lot traceability

Technical Advantages

Our custom WC-spec assemblies utilize optimized shielding architectures that provide up to 95% optical coverage, ensuring flawless signal attenuation and EMI/RFI defense in high-frequency radar and avionics environments. Built with flight-ready, cross-linked jackets, these ruggedized cable harnesses exhibit exceptional resistance to hydraulic fluids, abrasive wear, and extreme thermal cycling without degradation.

Let's Get Started

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Industry Applications

Avionics & Flight Control Systems

Delivers EMI-protected, low-loss signal routing for critical flight control computers, cockpit displays, and navigation subsystems operating in high-interference environments.

Defense Radar & Electronic Warfare

Ensures high-fidelity data transmission and maximum shielding effectiveness for tactical radar arrays, missile defense grids, and electronic countermeasure systems.

Unmanned Aerial Vehicles (UAVs)

Optimized, lightweight cable configurations designed to handle payload sensor data, remote telemetry, and power distribution under severe vibration profiles.

Naval & Shipboard Interconnects

Corrosion-resistant, heavily jacketed assemblies engineered to withstand continuous salt spray, high humidity, and harsh marine engine compartment fluids.

Military Ground Vehicles

Heavy-duty, overmolded wiring harnesses designed for C4ISR communication arrays, target acquisition systems, and ruggedized power grids within tactical armored vehicles.

Aerospace Launch Vehicles & Satellites

High-reliability, low-outgassing cable designs optimized for extreme thermal vacuums, high-g vibration, and critical multi-stage separation telemetry.

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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Having Doubts? Our FAQ

We have a strict "No Derived Materials" requirement for defense contracts. Can Frigate provide full material traceability for the MIL-DTL-27500 components?

Absolutely. Every assembly custom-built by Frigate comes with a comprehensive documentation package, including full material test reports (MTRs), Certificates of Conformance (CoC), and exact DFARS/ITAR compliance tracking back to the original wire and component manufacturers.

Can we specify alternative jacket materials or non-standard shielding coverages for high-vibration applications?

Yes, our engineering team works directly with your prints. While we build to standard MIL-DTL-27500 codes (such as TG, TH, or TE jackets), we can customize the outer braiding angle, utilize high-strength silver alloys, or apply specialized rugged overmolding to match your specific environmental stress requirements.

How does Frigate validate shielding effectiveness and signal integrity before shipping heavy-duty defense assemblies?

We subject 100% of our production runs to automated testing regimes. This includes continuous point-to-point wiring validation, high-pot/dielectric withstanding voltage (DWV) testing, insulation resistance testing up to 5000 Megohms, and custom insertion loss or cross-talk testing if dictated by your source control drawing.

Our project requires integrating proprietary connectors alongside standard military backshells. Can you accommodate hybrid designs?

Yes, we specialize in hybrid, build-to-print configurations. We routinely terminate MIL-DTL-27500 qualified raw cable to specialized commercial connectors, custom PCBs, or proprietary sensor housings while maintaining the specified shield termination and grounding methods across the assembly.

How do you handle component obsolescence or long lead times for specific MIL-spec backshells or connectors?

When components face long mill lead times, Frigate’s engineering team actively reviews your design to suggest qualified, form-fit-function cross-references or alternative cross-linked variants. We work with approved facilities to secure components early, minimizing bottlenecks for your production schedule.

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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

MIL-DTL-27500 Shielded Cable Assemblies

Product Description

Jacket Extrusion Materials

Voltage Rating

Operating Temperature

Dielectric Withstanding Voltage

Insulation Resistance

Connector Integration

Backshell & Boot Matching

Environmental Sealing

Testing Protocols

Compliance & Traceability

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

MIL-DTL-27500 Shielded Cable Assemblies

Get Latest Price

MIL-DTL-27500 Shielded Cable Assemblies

Get Latest Price