Polyimide Composite Insulated Aerospace Wires and Cables

Polyimide composite insulated aerospace wires and cables are designed for high-reliability wiring in aerospace, avionics, defense electronics, instrumentation, and harsh-environment systems. This product family includes HYY series construction options with polyimide composite film and PTFE film wrapping, supporting 600V AC rating, lightweight or standard designs, shielding, protective sheath options, and custom project requirements.

Polyimide Aerospace Wire
Composite Insulation
600V AC Rated
Shielded & Custom Options

Overview

Polyimide Composite Insulated Aerospace Wires and Cables are designed for high-reliability wiring applications in aerospace, avionics, defense electronics, instrumentation, and harsh electrical environments.

This product family uses a polyimide composite film and PTFE film wrapping insulation system to support compact size, lightweight construction, heat resistance, chemical stability, radiation resistance, and strong mechanical protection. It includes HYY series construction options for lightweight, standard, shielded, sheathed, and custom aerospace wiring requirements.

This page is intended for product selection. Exact specifications should be confirmed by selected construction code, conductor material, AWG size, shielding, sheath construction, color, and project standard before ordering.

Series Options

The table below helps buyers understand the main construction options within this polyimide composite aerospace wire and cable family before reviewing detailed drawings or datasheets.

Series / Code	Product Positioning	Typical Selection Scenario
HYY81 / HYY82	Lightweight polyimide composite insulated wire and cable options	For aerospace wiring where small outside diameter, lower weight, and compact routing are important.
HYY86 / HYY87 / HYY89 / HYY90	Standard or general-weight polyimide composite insulated wire and cable options	For high-reliability aerospace and defense wiring requiring stronger mechanical protection and stable insulation performance.
HYY91 / HYY92	Lightweight options with nickel-plated copper conductor configurations	For lightweight aerospace wiring where conductor type and high-temperature resistance must be selected by project requirement.
BYC Custom	Custom polyimide composite aerospace wire or cable construction	For projects requiring custom conductor, shielding, sheath, color, core count, or documentation support.

Features

Polyimide + PTFE Composite Insulation

Designed with a polyimide composite film and PTFE film wrapping system for demanding aerospace wiring applications.

High-Temperature Options

Selected conductor types support long-term operating temperatures up to -65°C to +260°C, depending on construction.

Lightweight and Compact Design

Available in lightweight and standard constructions to support space-saving and weight-sensitive aerospace systems.

Shielding and Sheath Options

Supports unshielded, braided shielded, and protective sheath configurations for EMI and environmental protection.

Harsh-Environment Performance

Suitable for applications requiring heat resistance, chemical resistance, radiation resistance, and mechanical durability.

Project-Based Customization

BYC Cables can review drawings, samples, or technical specifications to recommend a suitable construction.

Construction & Materials

The construction of this product family can be configured with different conductor materials, insulation structures, shielding materials, sheath systems, core counts, and color options. Final construction should be selected according to electrical rating, temperature requirement, routing space, EMI protection, and project standards.

Construction Options

Component	Available Options	Selection Notes
Conductor	Silver-plated copper, nickel-plated copper, silver-plated copper alloy, nickel-plated copper alloy, or project-specified conductor options	Conductor selection affects temperature rating, electrical resistance, weight, and application suitability.
Insulation	Polyimide composite film + PTFE film wrapping	Used for high-reliability aerospace wiring requiring compact size, heat resistance, and strong insulation performance.
Core Configuration	Single-core and multi-core options depending on selected construction	Available configurations may include single, pair, triad, and quad constructions depending on construction code.
Shielding	Unshielded, silver-plated copper braided shield, or nickel-plated copper braided shield	Shielding is selected when EMI protection or signal stability is required.
Protective Sheath	PTFE tape sheath or PI/FEP + PTFE composite sheath options depending on selected code	Sheath construction can improve mechanical protection, environmental resistance, and wiring durability.
Color & Marking	Multiple insulation and sheath color options	Color coding supports circuit identification and wiring management in aerospace systems.

Construction Differences

Series / Code	Construction Focus	Confirmed Information	When to Choose
HYY81 / HYY82	Lightweight construction	Designed as lightweight polyimide composite insulated wire and cable options, with compact outside diameter and low weight.	Choose when weight reduction and compact routing are important.
HYY86 / HYY87 / HYY89 / HYY90	Standard or general-weight construction	Designed for standard aerospace wiring applications requiring polyimide composite insulation and stable mechanical performance.	Choose when stronger general-purpose aerospace wiring performance is required.
HYY91 / HYY92	Lightweight conductor-specific construction	Includes lightweight configurations using nickel-plated copper conductor options according to the product code definition.	Choose when conductor type and lightweight design are both important for the project.
BYC Custom	Custom wire or cable construction	Conductor material, AWG size, shielding, sheath, color, core count, and documentation can be reviewed by project requirement.	Choose when the standard listed configuration does not fully match your drawing or specification.

Specifications

The specifications below are intended for preliminary product selection. Final values should be confirmed according to selected construction code, conductor material, AWG size, shielding, sheath construction, and project standards.

Product Family	Polyimide Composite Insulated Aerospace Wires and Cables
Reference Series	HYY series construction options
Reference / Product Standard	Developed with reference to SAE AS22759/80-92 and Q/HY105-2010 product standard
Rated Voltage	600V AC
Insulation System	Polyimide composite film + PTFE film wrapping
Temperature Rating	Up to -65°C to +260°C for selected conductor types; up to -65°C to +200°C for selected silver-plated conductor constructions
Available Sizes	26 AWG to 10 AWG in representative configurations
Shielding	Unshielded, silver-plated copper braided shield, or nickel-plated copper braided shield depending on selected code
Core Configuration	Single-core and multi-core constructions depending on selected construction code
Protective Sheath	PTFE tape sheath or PI/FEP + PTFE composite sheath options depending on selected code
Customization	Available based on drawings, samples, or technical specifications

For accurate quotation, please provide the target construction code if available, AWG size, conductor material, core count, shielding requirement, sheath requirement, color, operating temperature, and applicable drawings or standards.

Representative Performance Data

Performance Item	Confirmed / Representative Value	Notes
Dielectric Withstand	2500V / 5 min, no breakdown	Industrial-frequency voltage withstand test.
Insulation Resistance	>1500 MΩ·km / 5000 MΩ·kft	Representative value from product performance data.
Oxygen Index	>40%	Supports flame-retardant performance selection.
Low-Temperature Bend	Pass at -65°C ±3°C, 4 h	For low-temperature flexibility and mechanical reliability.
Thermal Aging	Pass at 290°C ±3°C, 500 h	Representative aging performance test.
Chemical Resistance	Hydrolysis resistant and passes solvent immersion testing	Suitable for demanding aerospace and harsh-environment applications.

Applications

Polyimide composite insulated aerospace wires and cables are suitable for high-reliability wiring systems where compact size, light weight, thermal stability, and harsh-environment resistance are important.

Aerospace Wiring Systems

For aircraft and spacecraft internal wiring where compact, lightweight, and high-reliability insulation is required.

Avionics & Instruments

For avionics, sensors, instruments, and electronic equipment requiring stable performance in demanding environments.

Defense Electronics

For defense electrical systems requiring heat resistance, radiation resistance, and reliable signal or power wiring.

Harsh-Environment Equipment

For systems exposed to high temperature, low temperature, chemicals, vibration, or limited installation space.

Selection Guide

Use this guide as a starting point. Final selection should be confirmed by conductor type, AWG size, shielding, sheath construction, temperature rating, installation space, and applicable project standards.

Requirement	Recommended Series	Selection Reason
Lightweight aerospace wiring	HYY81 / HYY82	Suitable for compact routing and weight-sensitive aerospace wiring requirements.
Standard high-reliability aerospace wiring	HYY86 / HYY87 / HYY89 / HYY90	Suitable for general aerospace wiring requiring stable insulation and mechanical performance.
Lightweight conductor-specific construction	HYY91 / HYY92	Suitable when lightweight design and specific conductor material requirements must be considered together.
EMI protection or signal stability	Shielded Option	Shielded constructions can be selected when electromagnetic interference protection is required.
Custom aerospace cable construction	BYC Custom	BYC Cables can review drawings, samples, and specifications to recommend a suitable construction.

Customization Options

BYC Cables can support custom polyimide composite aerospace wire and cable requirements based on drawings, samples, or technical specifications.

Conductor

Silver-plated copper, nickel-plated copper, silver-plated copper alloy, nickel-plated copper alloy, or project-specified conductor options.

Insulation

Polyimide composite film and PTFE film wrapping systems based on selected construction and performance requirements.

Size & Core Count

AWG size, conductor structure, single-core, or multi-core cable configuration can be reviewed by specification.

Shielding & Sheath

Unshielded, braided shielded, PTFE tape sheath, or PI/FEP + PTFE composite sheath options are available.

Color & Marking

Custom insulation color, sheath color, and identification marking can support aerospace wiring management.

Technical Support

Datasheets, specification review, and construction recommendations can be provided upon request.

Request a Quote

Please provide the target construction code if available, AWG size, conductor material, number of cores, shielding requirement, sheath requirement, color, operating environment, and applicable drawings or specifications.

FAQ

What are polyimide composite insulated aerospace wires used for?

They are used for high-reliability aerospace, avionics, defense, instrumentation, and harsh-environment wiring where compact size, light weight, thermal stability, and insulation reliability are important.

What is the insulation structure of this product family?

This product family uses a polyimide composite film and PTFE film wrapping insulation system. Depending on the selected construction code, protective sheath and shielding options may also be included.

What is the rated voltage?

The product family is listed as 600V AC. Final selection should be confirmed by conductor size, construction code, and project standard.

Can these wires and cables be customized?

Yes. BYC Cables can review custom requirements for conductor material, AWG size, shielding, sheath construction, color, core count, and documentation.

What information should I provide for quotation?

Please provide the construction code if available, AWG size, conductor material, core count, shielding requirement, sheath requirement, operating temperature, color, and any drawings or technical standards.