Aircraft wire system testing, certification, and qualification.https://lectromec.com/https://lectromec.com/blog/velocity-of-propagation-what-conductor-metal-really-changes-in-cable-design/https://lectromec.com/blog/velocity-of-propagation-what-conductor-metal-really-changes-in-cable-design/For low-latency cable design, the best path is not simply “use a better metal”; it is to engineer the electromagnetic field path by selecting the right dielectric and geometry, then choose the conductor system that preserves that performance in service. In this article, we review the concept of velocity of propagation, where it impacts system design, and the practical design factors for cable constructions.Tue, 07 Jul 2026 00:00:00 GMThttps://lectromec.com/blog/first-article-testing-of-wire-harnesses/https://lectromec.com/blog/first-article-testing-of-wire-harnesses/First-article testing of wire harnesses is a layered system-level verification plan often unique to the harness under test. Wiring harness first-article plans usually adapt existing wire, cable, and…Tue, 12 May 2026 00:00:00 GMThttps://lectromec.com/blog/mil-dtl-32630-vs-astm-b33-and-as29606/https://lectromec.com/blog/mil-dtl-32630-vs-astm-b33-and-as29606/Metal conductors have been the primary (and pretty much only) means of transferring electrical energy for centuries. With recent technological developments, it is possible to use alternative…Wed, 29 Apr 2026 00:00:00 GMThttps://lectromec.com/blog/hirf-and-ewis-in-the-age-of-high-voltage-aircraft/https://lectromec.com/blog/hirf-and-ewis-in-the-age-of-high-voltage-aircraft/High-Intensity Radiated Fields (HIRF) have often been viewed and treated mainly as an avionics certification problem. For modern aircraft, especially those moving toward higher-voltage power…Thu, 02 Apr 2026 00:00:00 GMThttps://lectromec.com/blog/faa-ewis-ica-update/https://lectromec.com/blog/faa-ewis-ica-update/AC 120-102B replaces AC 120-102A and modernizes the FAA’s operator guidance for EWIS ICA incorporation by tightening the legal framing of AC usage, updating oversight terminology and contact…Tue, 17 Mar 2026 00:00:00 GMThttps://lectromec.com/blog/comparison-of-mil-dtl-38999-and-mil-dtl-22992/https://lectromec.com/blog/comparison-of-mil-dtl-38999-and-mil-dtl-22992/In aviation Electrical Wiring Interconnection Systems (EWIS), the MIL-DTL-38999 is nearly synonymous with connector testing. Connectors qualified to the 38999 are considered suitable for rather…Wed, 28 Jan 2026 00:00:00 GMThttps://lectromec.com/blog/additive-manufacturing-of-ewis-components/https://lectromec.com/blog/additive-manufacturing-of-ewis-components/Additive manufacturing (AM), commonly known as 3D printing, is emerging as a promising method to produce certain EWIS components. This technology offers design freedom to create complex, lightweight…Mon, 05 Jan 2026 00:00:00 GMThttps://lectromec.com/blog/waic-in-aircraft-which-systems-will-stay-wired/https://lectromec.com/blog/waic-in-aircraft-which-systems-will-stay-wired/Miles of copper wire connect sensors, controls, and systems which add thousands of pounds to an aircraft, thus there has been a continuous drive for the use of lighter aluminum conductors, and maybe…Thu, 11 Dec 2025 00:00:00 GMThttps://lectromec.com/blog/an-exploration-of-as39029-part-1/https://lectromec.com/blog/an-exploration-of-as39029-part-1/The intermateability of electrical contacts is critical for electrical system reliability and performance. This article discusses one of many critical factors, the contact retention mechanism, which…Tue, 11 Nov 2025 00:00:00 GMThttps://lectromec.com/blog/potting-compounds/https://lectromec.com/blog/potting-compounds/Potting compounds covered in MIL-M-24041 are reliable compounds that have been part of aerospace wiring systems for decades. This article reviews a specific implementation of potting compounds and…Mon, 13 Oct 2025 00:00:00 GMThttps://lectromec.com/blog/wiring-diagram-guidance-for-aerospace-systems-mil-hdbk-863/https://lectromec.com/blog/wiring-diagram-guidance-for-aerospace-systems-mil-hdbk-863/Aircraft wiring schematics require clear standardized diagrams for design, fabrication, installation, maintenance, and safety assessments. This article explores the scope of MIL-HDBK-863, details it…Tue, 02 Sep 2025 00:00:00 GMThttps://lectromec.com/blog/cable-impedance-in-ewis-applications/https://lectromec.com/blog/cable-impedance-in-ewis-applications/Impedance matching is crucial to minimize reflection and signal loss in many high frequency EWIS applications. In this article, we discuss the factors impacting cable impedance, its impact on…Wed, 30 Jul 2025 00:00:00 GMThttps://lectromec.com/blog/sae-j1127-j1128-battery-cable-and-primary-wire-specifications/https://lectromec.com/blog/sae-j1127-j1128-battery-cable-and-primary-wire-specifications/The SAE J1127 and J1128 standards define two classes of automotive vehicle wiring. SAE J1127 covers heavy gauge *battery cables* (e.g. starter and chassis ground leads) and SAE J1128 covers lighter…Mon, 07 Jul 2025 00:00:00 GMThttps://lectromec.com/blog/quadrax-cable/https://lectromec.com/blog/quadrax-cable/In the case of high reliability, high-bandwidth data transmission, quadrax cables may emerge as a viable option for some designs. A typical quadrax cable has two layers of shielding each with at…Thu, 05 Jun 2025 00:00:00 GMThttps://lectromec.com/blog/iso-6722/https://lectromec.com/blog/iso-6722/The aerospace industry should consider automotive standards like the ISO 6722 as a basis for high-voltage wire qualification. Automotive and aerospace standards development around electrical wiring…Mon, 05 May 2025 00:00:00 GMThttps://lectromec.com/blog/benefits-of-supplying-a-completed-connector-harness-for-aircraft-installation/https://lectromec.com/blog/benefits-of-supplying-a-completed-connector-harness-for-aircraft-installation/The decision of whether to fully complete cable harness assembly before or during installation on aircraft is non-trivial and requires multiple engineering perspectives. The decision may depend on…Thu, 10 Apr 2025 00:00:00 GMThttps://lectromec.com/blog/deciphering-partial-discharge-test-results/https://lectromec.com/blog/deciphering-partial-discharge-test-results/Partial discharge testing serves as a valuable tool for assessing the health and reliability of wire and cable systems. Understanding the implications of PD test results, including PDIV, PDEV, and…Thu, 20 Feb 2025 00:00:00 GMThttps://lectromec.com/blog/the-complexity-of-fire-ratings/https://lectromec.com/blog/the-complexity-of-fire-ratings/Understanding the differences in fire and flammability tests for aircraft components is critical to ensuring safety and compliance with FAA regulations. In this article, we discuss the varying fire…Wed, 29 Jan 2025 00:00:00 GMThttps://lectromec.com/blog/connector-failure-modes-mating-demating/https://lectromec.com/blog/connector-failure-modes-mating-demating/EWIS maintenance sometimes includes the demating and remating of electrical connectors for testing, cleaning, removal to access other equipment, etc. The repeated action of mating/demating can cause…Mon, 06 Jan 2025 00:00:00 GMThttps://lectromec.com/blog/a-spark-of-holiday-cheer/https://lectromec.com/blog/a-spark-of-holiday-cheer/Every year, Lectromec creates a video to celebrate the holiday season. This year, we decided to utilize some of the lab's high voltage test equipment. This year's holiday video titled, "A Spark of…Thu, 19 Dec 2024 00:00:00 GMThttps://lectromec.com/blog/understanding-outcomes-of-scrape-abrasion-testing/https://lectromec.com/blog/understanding-outcomes-of-scrape-abrasion-testing/Scrape abrasion is a useful test for aviation wiring, although liable to inherent variability in test data. Thus, the results should be considered as a general assessment rather than a specific time…Thu, 21 Nov 2024 00:00:00 GMThttps://lectromec.com/blog/aluminum-conductors/https://lectromec.com/blog/aluminum-conductors/While there are benefits to replacing copper wires with aluminum, parts selection must align with the specific installation requirements. Here, we discuss the fundamentals of aluminum conductors…Thu, 05 Sep 2024 00:00:00 GMThttps://lectromec.com/blog/testing-and-qualification-of-fuses/https://lectromec.com/blog/testing-and-qualification-of-fuses/Aircraft electrical fuse testing includes electrical, mechanical, chemical, and thermal conditions that are representative of the aircraft in question. This article discusses the basics of electrical…Tue, 20 Aug 2024 00:00:00 GMThttps://lectromec.com/blog/high-voltage-low-current-material-arc-resistance-testing/https://lectromec.com/blog/high-voltage-low-current-material-arc-resistance-testing/Long-term exposure to high-voltage can cause an insulating material to break down and, over time, even form conductive paths along its surface. The ASTM D495 test method is a preliminary assessment…Fri, 26 Jul 2024 00:00:00 GMThttps://lectromec.com/blog/understanding-filter-line-cables-purpose-construction-and-key-concepts/https://lectromec.com/blog/understanding-filter-line-cables-purpose-construction-and-key-concepts/The primary purpose of filter line cables is to minimize EMI and RFI, which are prevalent in environments with high levels of electromagnetic noise. In this article we discuss the unique construction…Mon, 15 Jul 2024 00:00:00 GMThttps://lectromec.com/blog/high-voltage-dc-cable-shielding/https://lectromec.com/blog/high-voltage-dc-cable-shielding/Shielding on aerospace cables offers several benefits but can introduce some drawbacks that must be considered. In this article, we explore the pros and cons of using shielded cables on aircraft.Fri, 21 Jun 2024 00:00:00 GMThttps://lectromec.com/blog/as50881-and-connectors/https://lectromec.com/blog/as50881-and-connectors/Amidst the vast amount of aerospace standards, AS50881 stands out as a comprehensive guide to requirements to ensure wire termination safety specifically in connector installation and design. In this…Mon, 03 Jun 2024 00:00:00 GMThttps://lectromec.com/blog/inspectability-of-ewis/https://lectromec.com/blog/inspectability-of-ewis/Though EWIS should be protected from hazards such as tampering, FOD, and fluid exposure, the system does need to be periodically inspected and maintained throughout its service life. In this article…Mon, 01 Apr 2024 00:00:00 GMThttps://lectromec.com/blog/insertion-loss-and-attenuation/https://lectromec.com/blog/insertion-loss-and-attenuation/Insertion loss and attenuation are similar concepts, but one is assigned to a single component (insertion loss) whereas the other is assigned to generalized performance (attenuation). In this…Thu, 14 Mar 2024 00:00:00 GMThttps://lectromec.com/blog/the-use-of-splices/https://lectromec.com/blog/the-use-of-splices/Though useful in repairs and modification, overuse of splices can lead to serious electrical and mechanical problems in an electrical system. This article discusses the applications and restrictions…Tue, 20 Feb 2024 00:00:00 GMT