A Quick Guide to Mil-Spec Wires

Cable, wire, tubing, and accessories like such are used by the military in countless equipment. These equipment are required to work in harsh environments such as high temperatures, surface abrasion, unknown chemicals, tensile load, continuous stretch, and more. Due to the harshness and unpredictability of these conditions, all military equipment, especially wires demand higher-quality and need to pass the required acrimonious product testing. Mil-Spec wires are one of the most trusted and reliable wires used by the military.

Mil-Spec cable Wire

Mil-Spec wire stands for the military specifications for a wire. Therefore, they are built according to military specifications. They are often called as military wires. Mil-Spec wire is designed mainly for military applications, automobile industry, and aerospace purposes in accordance with US Department of Defense standards and specifications. These wires are ideal for being used for electronic applications in extreme conditions. They are exclusively used where high frequencies and high temperatures may be encountered. Some of the applications where they are used are- airframe wire, antennas, bus-bars, bonding moving parts, ground wires and much more.

Types of Mil-Spec wires-

  • Hook up wire
  • Power Wire
  • Dual shielding wire
  • Shielding wire
  • Pre-Twisted wire

Main Specifications of Mil-Spec wires-

  • They are present in a number of colors. It’s easy to understand or select them with the help of a chart. The wire colors are present in a coded form from 0 to 9 which explains different colors.
  • For example- 0 code stands for the black color of a wire whereas 9 stands for white color. When the wire is multicolored then you have more than one number.
  • Mil-Spec wires are lightweight and can withstand a high-temperature atmosphere.
  • These are insulated with the single layer of ethylene-tetrafluoroethylene (ETFE) special coating that can work even in 150 degrees C or 302 degrees F.
  • If compare with the other wires, they are cost-effective. It has a tin-plated copper conductor and is measured at 600V.
  • Mil-Spec wires present with dual insulation offers abrasion protection and better strength that can be used in various fields.

KC Electronics is a dedicated and reliable firm that fulfills all the needs of their clients like- Mil-Spec wire, tubing, connectors, batteries and all other electronic items.

Different Benefits And Uses Of Teflon Wire

When it comes to wires, the universe of wires is not constrained to few conventional wires, for example, copper wires etc. The progressive change took them facilitate which give solid variations like Silver Plated Copper Electrical Wire, PTFE Insulated Silver Plated Copper Wire, Silver Coated Copper Wire, and so on.

Teflon wires are additionally a noteworthy piece of the universe of wires that have been viewed as significant for its charming properties. It has noteworthy resistance properties of the chemicals, temperature, dampness, and power which make it simple to enter the opposition without significantly more noteworthy exertion.

The perfect material is considered in influencing the wires for its unwavering quality and strength to notwithstanding for the most strenuous applications.

Effective Aspects Of Teflon Wires:

  • This kind of wires have high dielectric strength
  • These are extremely high operating temperatures.
  • Contains low dissipation factor and also unchanged by susceptibility to humidity, liquid, and moisture

Along with these, other features are as following:

  • These Insulated wires are suitable for a wide frequency range
  • Silver plated conductors or your choice of conductor
  • Provides resistance to UV radiation, stress, mould, and chemicals
  • PTFE insulated wires are not subject to creeping or deformity over time

Teflon Wire

Various Uses Of Teflon Wires:

There are numerous qualities such as electrical resistances, temperature, moisture and chemical that make it an excellent material whenever tools, products, and components require being reliable in even the most demanding applications.

  • In Medical Field:
    PTFE covered wires give perfect scope and assurance when medical gadgets require a smooth coating that is smooth, thin, artificially idle, exact and equipped for withstanding a wide assortment of conditions.

It’s non-chipping complete settles on it a covering of decision when complete quality is foremost for the two feel and administrative details. At PWI, our forte is protecting the sort of miniaturized scale PTFE covered wire that is habitually utilized as a part of the therapeutic instrumentation, inserts, and different gadgets.



An Insight Into Versatile Fluoropolymers In Everyday Life

While majority of people have heard of fluoropolymers at some point in their lives there are some people who might not have heard of it. But there is one commonly used fluoropolymer we have all heard of and it is  known as Teflon.

Teflon is a very versatile polymer and is used in variety of products like cookware, teflon wire and more. These products are later used in various industries such as automotives, electronics & communications and national security. Several notable benefits of using these fluoropolymers in the business are discussed in the following points:


  • Protect Firefighters: They are used to make fire-proof fabrics and water resistant fabrics to resist water and abrasion as they move ahead to provide insulation against flames.
  • Safe Flights: While other insulation types continue to be a fire hazard in airplanes still, the fluoropolymers fill in the gaps and provide the right amount of insulation required for a safe flight.  
  • Safety Gears: All the factory workers across the globe wear a safety gear in order to protect themselves. These gears come with a fluoropolymer coating, PTFE to be precise. It keeps them protected from various hazards including stuff like acid or alkaline solutions.
  • Safety At Work: All workplaces are prone to fire hazards with usual insulation materials in play. But, these threats can be eliminated using the fluoropolymer coating as they protect the wires. Such wires are used in phones, electronics and computers to keep the employees safe was they operate them. The home wiring is also protected by the material of same configuration.

Therefore, fluoropolymers play a major role in our day to day lives without us being aware about it. They serve as the best protective coatings under all conditions and can be a great deal of safety under varying working conditions. Application of these do require a great deal of knowledge and expertise, so you must deal with a firm with the right qualifications and proven track record.

Quality standards for the wires used by military

Protecting the nation is the responsibility of military. In regard to this, military requires the best possible products. This includes quality electrical wires for its operations.

Every distributor needs to meet the standards for wires before providing them to the Military. Since they have to work in the harshest environments on earth and have the toughest job to do, it is important to provide them reliable and consistent performing products.

mil spec wireQuality products are reliable enough to work in harsh weather conditions like very low or high temperatures or any other difficult situations.
Commonly used wire for military purpose is mil spec wire. This wire needs to be reliable and qualify certain specifications.

While manufacturing this wire, distributers make sure to meet the standards determined by the United States Department of Defense.

Quality standards set for these wires are –

Electrical characteristics – Cables required for military purposes need to have excellent electrical characteristics such as capable of handling low to high voltage. These are designed specifically according to specific needs.

Good insulation material – Cables need to have good insulation property. These wires are designed to have good insulation because it affects the performance of appliance. Wires with good insulation material work best in tough conditions.

Low power loss – Wires to be used for military purposes should have low power loss ability as those that are to be used in rough environments. The wires with low power loss keep the performance of the appliance up.

Tolerance and resistance – These wires should have a good tolerance and resistance level. This is because they are required to function in both high and low temperatures. Moreover, it should be resistance to the water, oil, chemicals, and other solvents.

Mil spec wires are designed specifically for defense purposes. These are designed in different sizes, styles, insulation thickness, colors, and voltage rating.

These wires are commonly used in aircrafts, ground communications and equipment, and several other applications because it provides protective covering and shielding to the electronic circuit.

What aspects are essential to consider while purchasing Mil Spec Cable Tie?

Quality of cables cannot be overlooked when it comes to purchase of military cables. There are many factors to take into consideration while purchasing cables, in order to avoid risks like device failure during the tough military time.

Mil spec cable tieHere are few of those aspects or factors that are to consider when purchasing Mil Spec Cable Tie

  • Weather resistant- This is the first property on which cables needs to standby. Cables withstanding tough weather conditions such as extreme temperature changes, humidity, and more are durable. Neglecting this factor degrades performance of a device. This hampers work of military when they require it the most. To make cables withstand bad weather conditions, special material is used like Nylon because it is UV stabilized and has good resistant factor.

  • Flammability rating- As military workspace involves harsh environmental conditions cables require to have good flammability rating that is of UL 94 V-2.

  • Reliability- Cables should withstand extreme military harsh conditions, so that military people can rely upon the devices. In such case, reliability of cables is necessary to check.

  • Tensile strength- Cables should have good tensile strength, so that it could easily stretch or pulled when wrapping around a device or inserting in a self-locking head is to be done. Tensile strength of military cables should have 50 lbs.

  • Temperature rating- Military workspace involves tough environment. To standby it, cables should meet excellent dielectric properties and temperature level of approx. -40°F to 185°F.

  • Compatibility- Last but not the least factor that is must to check is work compatibility of Mil Spec cables. This ensures working ability of cables in devices, which are being use for different applications during military needs.

From the above stated points, you must have got an idea what factors are essential to consider when purchasing Mil Spec wires. This calls for a seeking a reliable manufacturer.

With numerous manufacturers in market, it is difficult to make out which manufacturer can provide you the best product. In such cases, considering factors like experience, reputation, work credibility, timely delivery of products is essential.

In addition to this, it is also must to check the quality of military electronic products, after all quality only defines the working and durability of the product. The U.S. Department of Defense has set some testing standards on which military products need to standby.

Top qualities that are needed in the electrical wires for military

Military bears the responsibility of protecting its nation. For this important and tough task, army requires few of the best possible products including electrical wires. Army has some specific quality standards for wires, which every distributer needs to qualify.

Since army works in few of the harshest environments, which means that its applications should be capable of handling all type of harsh weathers and conditions. They need reliable and consistent performing products that can work properly even in very low or high temperatures and other difficult situations.

Military only uses mil spec wire that meets all requirements and standards. These standards are determined by the United States Department of Defense. These products are specifically made to qualify army’s certain specifications. Army uses variety of quality cables in the aircrafts, marine and several other applications. It is used for protective covering, shielding, to complete electronic circuit and many more tasks.

Quality standards for the wires used by military are –

Electrical characteristics – Military requires cables with excellent and stable electrical characteristics. These products work in the tough environments still they need to execute their work properly. This is why army selects only those electric cords, which meet its specifications for the electrical characteristics. These products should be capable of handling low to high voltage.

Good insulation material – Military also needs wires with good insulation material. There are varieties of materials available for cable insulation. This material affects the performance of cables. This is why the insulation material should be good for the best performance in tough conditions. PVC and Teflon insulated products are considered good for this military purposes.

Low power loss – Power loss is a disadvantage in electrical cords. Army works in rough environments where every aspect is valuable including electricity. This is why, they need cables with lowest possible power loss abilities. They must reduce power loss in electronic applications while keeping up the performance.

Tolerance and resistance – Wires in military should be capable of function in high or low temperatures. It should be capable of withstanding harsh weathers conditions. Resistance to the water, impact, oil, chemicals and other solvents is also an ability needed in the mil spec cables. Water resistance makes it possible to use these cables in marine applications.

These wires are used by army in different sizes, styles, insulation thickness, colors and voltage rating etc., according to the requirements of electronic application. Some of these products can fit all type of applications.