The electrification of aerospace and defence is a complete rethinking of flight. From advanced electric propulsion systems to digitally interconnected power networks, every cable, connector and material choice now carries the weight of performance, safety and sustainability. The drive to reduce emissions and improve efficiency has shifted the sector’s engineering priorities toward lighter, smarter and more electrified systems. Here, Bo Corn, strategic advisor at WireMasters, explains how electrification is transforming cable design and performance across the aerospace and defence industries.

At the heart of the electrification shift lies the electrical system, the nervous system of the aircraft. Where mechanical and hydraulic components once dominated, high-voltage distribution and intelligent power management now take the lead. The challenge is monumental: designing cabling systems that can transmit greater power through smaller footprints, resist extreme altitudes and temperatures and integrate seamlessly with next-generation avionics and propulsion technologies.

Designing for power and precision

Electrification demands a new approach to how aerospace and defence engineers design and specify cabling. Modern systems must handle higher voltages without adding excess weight, a balance achieved through advanced materials and smarter design methodologies.

Fluoropolymers along with other materials such a Polyimide are continuing to provide higher dielectric strength while minimising arcing, allowing cables to deliver more power per unit mass. These innovations enable smaller, lighter wiring that fits within increasingly compact aircraft structures, extending flight range and improving overall performance.

Digital twins, virtual replicas of electrical systems are now playing a pivotal role in achieving these design breakthroughs. Engineers can simulate how a cable assembly behaves under different electrical loads, temperatures and vibration conditions before any physical prototype is built. This approach not only accelerates development but also ensures safety and compliance in the face of rising voltages and complex hybrid-electric architectures.

Precision manufacturing further refines this process. Robotics, AI-driven quality control and advanced extrusion technologies allow suppliers to achieve microscopic tolerances in conductor diameter, insulation thickness and shielding alignment. These refinements are essential for maintaining impedance, signal integrity and long-term reliability across an aircraft’s electrical network.

Managing heat, noise and weight

As systems become more electrified, engineers face an escalating challenge: controlling heat and electromagnetic interference (EMI) within ever-tighter packaging. Higher current densities increase heating and reduced space limits airflow, demanding innovative materials with superior thermal conductivity. New generations of polymer insulation not only withstand higher operating temperatures, but also enhance heat dissipation, keeping critical components stable even under peak loads.

Meanwhile, EMI has become a defining concern. Foil-and-braid shielding, precise grounding and the separation of power and signal lines remain standard practice, but material science is taking these protections further. Aluminium and hybrid metal composites are replacing heavier traditional shielding, striking the ideal balance between conductivity and mass reduction.

Weight optimisation runs through every aspect of electrified design. Conductors are increasingly made from aluminium or specialised alloys to reduce density without sacrificing strength. Foamed fluoropolymers and air-inserted dielectric layers minimise material mass while preserving electrical integrity. In high-voltage environments, these refinements translate directly into improved endurance, range and payload capacity, a critical advantage for both military and commercial platforms.

Adapting to new standards and materials

Electrification is reshaping not just design, but qualification itself. Standards such as UL 2556 and evolving Electrical Wiring Interconnection System (EWIS) requirements now push cables to withstand greater dielectric stress, thermal extremes and EMI exposure. These standards ensure aircraft wiring performs safely and reliably under demanding flight conditions. Manufacturers are responding with more rigorous testing and accelerated life-cycle simulations that mirror real environments.

At the same time, growing scrutiny over per- and polyfluoroalkyl substances (PFAS), chemicals used in many fluoropolymer insulations has forced the industry to seek alternatives like polyimide, valued for its heat resistance and durability. However, qualifying these replacements takes years, making supply chain stability essential.

Looking ahead, the next generation of aerospace cables will combine high-voltage tolerance, lightweight construction and embedded intelligence. Materials with built-in sensing could soon monitor temperature, strain and EMI in real time, while digital twins and AI-driven manufacturing set the stage for smarter, more connected flight systems.

Electrification is redefining every aspect of aerospace and defence engineering. From precision manufacturing to advanced insulation chemistry, success depends on materials that perform flawlessly in extreme environments.

WireMasters is leading this transformation with next-generation cabling solutions engineered for high-voltage, high-performance systems. To learn more about how WireMasters is driving electrification in aerospace and defence visit www.wiremasters.com.