In aerospace, failure isn't an option—every material has a mission.

Wire harness assemblies in aircraft operate under intense pressure: from punishing heat and cold to constant vibration and electromagnetic interference. With safety and compliance at the forefront, these systems must meet strict standards like AS50881, MIL-W-22759, and FAR Part 25. That means every wire, sleeve, shield, and label must be chosen with precision.

Here are 22 materials that aerospace engineers and procurement teams rely on to meet—and exceed—aviation-grade expectations.

Conductors that power performance

1. Tinned Copper
   The go-to choice for reliable conductivity and resistance to corrosion. Its tin coating also improves solderability and aging resistance.
   
   

2. Silver-Plated Copper
   Known for excellent conductivity and high-temperature durability—often used in military-grade and high-frequency aerospace systems.
   
   

3. Nickel-Plated Copper
   A favorite for extreme heat zones, this material can take temperatures above 200°C while resisting oxidation.
   
   

4. Aluminum
   While trickier to terminate, aluminum provides a lightweight solution for large-gauge applications, helping reduce total system weight.
   
   

Insulations that survive the skies

5. PTFE (Polytetrafluoroethylene)
   With unmatched thermal stability (up to 260°C), PTFE delivers insulation that won’t crack under pressure—chemically inert and flame resistant.
   
   

6. ETFE (Ethylene Tetrafluoroethylene)
   A lighter, rugged alternative to PTFE that resists radiation and chemicals. It’s a common choice for modern aerospace wiring specs.
   
   

7. XL-ETFE (Cross-linked ETFE)
   Built for abrasion and mechanical strength, it offers long-term performance in demanding flight conditions.
   
   

8. PFA (Perfluoroalkoxy)
   Combines PTFE-like thermal strength with greater flexibility—ideal for tight routing or dynamic assemblies.
   
   

9. Polyimide (Kapton®)
   Light, durable, and heat-tolerant. Frequently used in space and aerospace harnessing due to its impressive flame resistance and minimal weight.

Shielding materials that block interference

10. Braided Copper Shielding
    Excellent for both grounding and EMI protection. Can be customized with tin, silver, or nickel plating based on the environment.
    
    

11. Aluminum-Mylar Foil
    Lightweight shielding solution, often paired with a drain wire for solid grounding—ideal for tight spaces or layered shielding.
    
    

12. Nickel-Coated Copper Shields
    Adds ruggedness for high-heat, corrosive, or fuel-exposed environments. Frequently used in engine compartments.
    
    

13. Stainless Steel Braid
    When mechanical strength is paramount, stainless steel offers resilience—though with a weight trade-off.

Jackets and sleeving that protect and organize

14. FEP Jacket (Fluorinated Ethylene Propylene)
    Durable, transparent, and chemically resistant. FEP-jacketed cables are common in signal applications and harsh environments.
    
    

15. PET (Polyester) Sleeving
    Lightweight and expandable for flexible bundling. While not high-heat rated, it’s often used with protective coatings.
    
    

16. Nomex® Sleeving
    Designed for thermal and flame protection, it’s a must-have in high-temperature areas like engine bays or power systems.
    
    

17. Tefzel® (ETFE Trade Name)
    A common choice for ultra-thin, lightweight jacketing where space and weight are limited.
    
    

18. PVC (for ground-only applications)
    Not suited for flight, but often used in ground testing or training setups for cost-effectiveness and flexibility.
    
    

Tapes and wraps that hold it together

19. Polyimide Tape
    A go-to for high-temp and non-stick performance—perfect for labeling or insulation in hot zones.
    
    

20. Glass Cloth Tape
    Offers reinforcement and abrasion protection. Commonly used for heavy-duty bundling in high-friction areas.
    
    

21. PTFE Tape
    Provides clean, high-temperature insulation and moisture resistance—used in areas with dynamic flex or thermal stress.
    
    

Identification that lasts

22. Heat-Shrink Polyolefin Markers
    The standard for permanent wire ID. They’re rugged, heat-resistant, and compliant with SAE-AS81531 durability tests.
    
    

Final approach: material choices that make or break your design

Wire harnesses don’t just carry signals—they carry responsibility. The materials you choose directly impact everything from aircraft weight and performance to compliance, durability, and service life. Whether you're designing from scratch or revalidating an existing harness, these 22 materials offer the blueprint for reliability.

Make your harness decisions with care—and make sure they’re built to fly.