P.J. Wagner, J. Rust
Minnesota Wire, Minnesota, United States
Keywords: aerospace, lightweight, high temperature, flexible RF cables
Radio frequency (RF) and conductive data cables are essential to modern military platforms, transporting critical data between sensors, processors, and actuators in UAVs, missiles, space vehicles, and other Defense systems. These cables face extreme conditions and tight spaces throughout their service life. Their reliability is crucial for mission success, requiring resistance to electromagnetic pulse (EMP) attacks and robustness against kinetic threats. Standard signal wires, which make up to 80% of military aircraft wiring, are often shielded with nickel-plated copper for durability, despite the added weight and susceptibility to bending fatigue. In UAVs, missiles, and satellites, thermal, weight, and volume constraints limit the use of standard shielding, affecting performance. Recognizing the need for better data transmission cables, Minnesota Wire and Cable partnered with Huntsman Advanced Materials to develop lightweight MILSPEC cables using Miralon® carbon nanotubes (CNT). These CNT-based materials offer high strength, suitable service temperatures, and improved platform reliability, leading to significant weight and thermal efficiency improvements. This presentation will explore the challenges of wired data transmission on military platforms, the role of CNT-based cables in addressing these issues, and future developments in CNT-based cabling for military applications.