Aerospace Connectivity: Lightweight Electrical Architectures for the Next Generation of Aviation

In aerospace, every kilogram matters. Aircraft manufacturers, eVTOL developers, and defense integrators are under increasing pressure to improve energy efficiency, reduce emissions, maximize payload capacity, and lower operating costs. As initiatives such as ICAO’s Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA), ReFuelEU Aviation, and broader sustainability targets accelerate the industry’s transition toward lighter aircraft, conventional wiring harnesses have become an increasingly important area for optimization.

New Cable Corporation’s flat cable technology offers a new approach to aerospace electrical distribution by replacing bulky wire harnesses with lightweight, highly integrated flat cable architectures. The result is a significant reduction in wiring mass and installation complexity while maintaining the electrical, mechanical, and environmental performance required by demanding aerospace applications.

Aerospace programs require exceptional reliability, traceability, and quality assurance. Our development and manufacturing processes are designed to support the rigorous quality management principles expected throughout the aerospace industry.

Our design and production methodologies support the risk management, configuration control, documentation, and traceability practices associated with AS9100 quality management systems. These principles help ensure consistent manufacturing quality throughout the product lifecycle.

Safety remains the highest priority in every aerospace application. Flat cable constructions can be manufactured using the same insulation systems, shielding materials, and protective layers commonly used in qualified aerospace wire and cable products. Depending on customer and platform requirements, materials can be selected to support compliance with applicable aerospace fire, smoke, toxicity, environmental, and durability requirements.

Flat cable assemblies can be engineered to support qualification programs aligned with applicable aerospace requirements, including environmental testing, vibration resistance, thermal cycling, mechanical durability, and electromagnetic compatibility considerations. Qualification approaches may be tailored to commercial aviation, defense, space, or advanced air mobility platforms.

Weight reduction remains one of the most effective methods for improving aircraft efficiency. By reducing wiring system mass, flat cable architectures can contribute to lower fuel consumption, improved payload capability, and extended operational range while supporting broader industry sustainability initiatives such as CORSIA and ReFuelEU Aviation.

The future of aviation is increasingly electric. eVTOL aircraft, electric regional aviation, cargo drones, and hybrid-electric propulsion systems all depend on maximizing the useful energy available from onboard batteries and power systems.

Because energy storage remains one of the primary constraints in electric aviation, every component must be optimized for weight and efficiency. Flat cable architectures enable engineers to reduce harness mass, improve packaging efficiency, maximize usable internal volume, and simplify electrical integration throughout the aircraft.

The technology is particularly well suited for:

• eVTOL and advanced air mobility platforms
• Electric and hybrid-electric aircraft
• Unmanned aerial systems (UAS)
• Satellite and space applications
• Commercial aviation cabin systems
• Aerospace power distribution networks
• Sensor, communication, and avionics integration

One of the key advantages of flat cable technology is material flexibility. Flat cables can be manufactured using many of the same conductor materials, insulation systems, shielding technologies, and protective layers used in conventional aerospace cable assemblies.

The flat architecture also enables the use of advanced film-based polymer systems that are naturally compatible with roll-to-roll manufacturing processes. This creates opportunities for highly integrated electrical structures while maintaining compatibility with aerospace qualification requirements.

As aircraft become increasingly electrified, wiring systems must evolve beyond traditional harness architectures. New Cable Corporation’s flat cable technology provides aerospace engineers with a scalable platform for reducing weight, simplifying installation, improving system integration, and supporting the next generation of sustainable aviation.

Depending on application and customer requirements, aerospace cable systems may be designed and qualified in consideration of standards and frameworks such as:

• AS9100 Aerospace Quality Management Systems
• RTCA DO-160 Environmental Conditions and Test Procedures for Airborne Equipment
• FAA airworthiness requirements
• EASA certification requirements
• FAR/CS 25.853 flammability requirements
• EN aerospace cable and interconnection standards
• Applicable MIL-DTL specifications for defense programs
• ICAO CORSIA sustainability framework
• ReFuelEU Aviation initiative