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Hook-up & equipment wiresNEMA WC 27500 · MIL-DTL-27500AS22759 Primary · 600 V−65…+150 / +200 °C Avionics

MIL-27500 Aerospace Multicore Shielded CableNEMA WC 27500 (MIL-DTL-27500) 600 V aerospace fluoropolymer shielded & jacketed cable

Airframe, avionics and defence shielded single-core, twisted-pair, triad and multicore cable built to NEMA WC 27500 (MIL-DTL-27500) using SAE AS22759 (M22759/16, /32, /34, /11) ETFE, XLETFE or PTFE primary wires, plated copper braid and FEP/ETFE/PTFE jacket.

Flame-retardant
Oil-resistant
Low-EMC design
Ozone, UV & moisture
Order designation
M27500-22TE2T14 (2×22 AWG Pair)
Outer Ø min
3.1 mm
Outer Ø max
3.4 mm
Weight ≈
25 kg/km
Min. bend R
20 mm
Check against my drumAll sizes (16)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Voltage rating
600 V RMS
SAE AS22759 primary wire rating
Temp. rating
−65…+150/+200 °C
+150 °C (tin Cu) · +200 °C (silver Cu)
Primary wires
SAE AS22759
M22759/16, /32, /34, /43, /11, /80–92
Shield coverage
≥ 85 % braid
Tin-, silver- or nickel-Cu braid
Fire & smoke
FAR 25.853
Passes 60° aerospace Bunsen burner test
Range
1–10C · 26–10AWG
Single, pair, triad, quad & multicore

Typical values for this cable type, based on NEMA WC 27500 (MIL-DTL-27500) · SAE AS22759 — confirmed in the datasheet and quotation for your order.

Application fit

Is MIL-27500 right for your machine?

NEMA WC 27500 (formerly MIL-DTL-27500) uses a modular part-numbering matrix combining any qualified SAE AS22759 fluoropolymer primary wire with single or double metallic braid shields (`T`, `S`, `N`, `V`) and fluoropolymer jackets (`06`, `14`, `23`) for aircraft, UAV, satellite, motorsport and defence harnesses.

Fixed installation

Suitable

Aircraft avionics bays, flight-control actuators, engine nacelles, military vehicles and motorsport looms.

VFD inverter to AC motor screened feeder

Suitable

≥85 % (or double-shield) tin-, silver- or nickel-plated copper braid provides superior HIRF/lightning and EMI immunity.

Trailing & towing

Not suitable

Aerospace and defence vehicle harness cable; not for industrial ground drag.

Use EN 50264-2-2

Energy chain / drag chain

Not suitable

For 300 V European railway rolling-stock thin-wall screened pairs/quads, select EN 50306-3.

Use EN 50306-3
Typical machinesCommercial & military airframe avionics baysUAVs, eVTOLs, satellites & launch vehiclesDefence land vehicles, radar & naval mastsFormula 1 / endurance motorsport engine loomsDownhole oilfield & vacuum chamber instrumentation

Construction

Layer by layer

Shown: M27500-22TE2T14 (2×22 AWG Twisted Pair) — two SAE AS22759/16 (ETFE, +150 °C) or AS22759/32 (XLETFE, +150 °C) 19/34 tinned-copper cores (white & white/blue stripe), ≥85 % tinned-copper braid shield ('T') and white extruded ETFE outer jacket ('14').

1234
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
119- or 37-strand plated copperConcentric-stranded tin-plated (+150 °C), silver-plated (+200 °C) or nickel-plated (+260 °C) copper or high-strength copper alloy (26–10 AWG)SAE AS22759 · ASTM B33 / B298 / B355
2AS22759 fluoropolymer primary coresExtruded ETFE (M22759/16, 'TE'), irradiated cross-linked XLETFE (M22759/32–/46, 'SB'/'SD'), or PTFE (M22759/11, 'RC') cabled 1 to 10 coresSAE AS22759 · NEMA WC 27500 Table I
3≥ 85 % plated-copper braid shieldSingle or double round or flat-filament braid in tin-Cu ('T'/'G'), silver-Cu ('S'/'F') or nickel-Cu ('N'/'H')NEMA WC 27500 Table II
4Fluoropolymer outer jacket (14 / 06 / 23)Thin-wall extruded white ETFE (Style 14), clear/tinted FEP (Style 06), irradiated XLETFE (Style 23) or sintered PTFE tape (Style 02/09)NEMA WC 27500 Table III · FAR 25.853

M27500-xxTE / SB / SD .. T14 (+150 °C Tinned Cu, ETFE / XLETFE, ETFE Jacket)

Airframe & defence harness standard using AS22759/16 (TE) or AS22759/32 (SB) cores, tin-Cu braid (T) and ETFE jacket (14)

M27500-xxTG / SE / RC .. S06 / S23 (+200 °C Silver Cu, FEP / XLETFE Jacket)

High-temperature avionics & engine-zone cable using silver-plated copper cores (AS22759/18, /34, /11) and silver-Cu shield (S)

M27500 Double-Shielded HIRF / Tempest Configurations (V / W / Y)

Dual concentric silver- or tin-plated copper braids for lightning-strike and high-intensity radiated field (HIRF) zones

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on NEMA WC 27500 (MIL-DTL-27500) · SAE AS22759. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage
600 V RMS (from sea level to 60,000+ ft altitude depending on primary wire style)
Dielectric withstand voltage
1.5 kV to 2.5 kV AC RMS for 1 min · 3.4–5.0 kV spark test
Shield optical coverage
≥ 85 % minimum optical coverage across all NEMA WC 27500 shield styles
Max. DC conductor resistance (20 °C)
26 AWG (19/38): ≤ 135 Ω/km · 24 AWG (19/36): ≤ 86.0 Ω/km · 22 AWG (19/34): ≤ 53.1 Ω/km · 20 AWG (19/32): ≤ 32.0 Ω/km · 16 AWG (19/29): ≤ 14.9 Ω/km

Thermal

Operating temperature range
−65 °C to +150 °C (tin-plated Cu, TE/SB/14) · −65 °C to +200 °C (silver-plated Cu, TG/SE/RC/06/23) · up to +260 °C (nickel-Cu / PTFE)
Short-circuit / solder heat
+150 °C to +250 °C (5 s)

Mechanical

Min. bending radius
6 × overall diameter (fixed airframe harness) · 10 × overall diameter (flexing)
Laser markability
White ETFE / XLETFE jackets (Styles 14 & 23) are formulated for high-contrast UV laser wire identification per SAE AS5649

Resistance

Aerospace flammability
Passes FAR 25.853 (14 CFR Part 25 Appendix F) 60-degree vertical burn and smoke emission tests
Aviation fluids & Skydrol
Fluoropolymer insulation and jacket resist Jet-A fuel, MIL-PRF-5606 / Skydrol hydraulic fluid, MIL-PRF-23699 turbine oil and de-icing fluids

Reference standards

Primary cable standard
NEMA WC 27500 (superseding MIL-DTL-27500 / MIL-C-27500)
Primary wire standard
SAE AS22759 (superseding MIL-W-22759) — Styles /11, /16, /18, /32, /34, /41, /43, /80–92
Airframe installation
Compliant with SAE AS50881 (Aerospace Vehicle Wiring)
RoHS & REACH
2011/65/EU (RoHS 2) compliant

Identification

Core colour coding
MIL-STD-681 Method 1 (white base with helical colour stripes: 1=White, 2=White/Blue, 3=White/Orange, 4=White/Green) or Method 2 solid
Part number syntax
M27500-[Dash][AWG][WireType][Cores][Shield][Jacket] (e.g. M27500-22TE2T14)
Customs tariff (HS)
8544.49 (insulated conductors ≤ 1000 V)

Sizes

16 standard MIL-27500 configurations

Typical NEMA WC 27500 (MIL-DTL-27500) · SAE AS22759 outer diameter limits, copper content and cable weight.

Dimensions & weights
Order designationCores × mm² / AWGAWG ≈Outer Ø min
mm		Outer Ø max
mm		Copper
kg/km		Weight ≈
kg/km		Min. bend R
mm		Enquiry
1-Core Shielded & Jacketed Aerospace Wire (M27500-xxTE1T14 / SB1T23)
M27500-26TE1T14 (1×26 AWG)1×26 AWG (0.15 mm²)261.71.95911
M27500-24TE1T14 (1×24 AWG)1×24 AWG (0.24 mm²)241.82.061112
M27500-22TE1T14 (1×22 AWG)1×22 AWG (0.38 mm²)222.02.281413
M27500-20TE1T14 (1×20 AWG)1×20 AWG (0.60 mm²)202.32.5111815
2-Core Shielded Twisted Pairs (M27500-xxTE2T14 / SB2T23 / SE2S23)
M27500-26TE2T14 (2×26 AWG Pair)2×26 AWG (0.15 mm²)262.52.891516
M27500-24TE2T14 (2×24 AWG Pair)2×24 AWG (0.24 mm²)242.83.0111918
M27500-22TE2T14 (2×22 AWG Pair)2×22 AWG (0.38 mm²)223.13.4152520
M27500-20TE2T14 (2×20 AWG Pair)2×20 AWG (0.60 mm²)203.63.9223423
M27500-18TE2T14 (2×18 AWG Pair)2×18 AWG (0.96 mm²)184.14.5314727
M27500-16TE2T14 (2×16 AWG Pair)2×16 AWG (1.23 mm²)164.65.0395830
3-Core Shielded Triads & 4-Core Quads (M27500-xxTE3T14 & xxTE4T14)
M27500-24TE3T14 (3×24 AWG Triad)3×24 AWG (0.24 mm²)243.03.2152420
M27500-22TE3T14 (3×22 AWG Triad)3×22 AWG (0.38 mm²)223.43.6213222
M27500-20TE3T14 (3×20 AWG Triad)3×20 AWG (0.60 mm²)203.84.2294425
M27500-24TE4T14 (4×24 AWG Quad)4×24 AWG (0.24 mm²)243.33.5183021
M27500-22TE4T14 (4×22 AWG Quad)4×22 AWG (0.38 mm²)223.74.0264024
M27500-20TE4T14 (4×20 AWG Quad)4×20 AWG (0.60 mm²)204.24.5375627
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Dimensions and weights are typical values per NEMA WC 27500 (MIL-DTL-27500) · SAE AS22759. Minimum fixed bending radius shown is 6 × OD.

Reel check

Will it fit your machine?

A first screen using datasheet values. Engineering confirms drum geometry, acceleration and tension with your quotation.

Check results

Drum core 300 mm ≥ 40 mmBending radius OK (6 × OD 3.4 mm)
Minimum bending radius
20 mm
Min. drum core diameter
≈ 40 mm
Cable weight on drum
1.3 kg
Copper content
0.8 kg
Indicative only: based on the datasheet outer diameter and 6 × OD bending radius. Current derating for wound layers per DIN VDE 0298-4 is assessed separately.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
AC dielectric voltage test2.5 kV AC (50/60 Hz)Every manufactured length
Conductor DC resistanceIEC 60228 / ASTM (tinned copper)Every manufactured length
Sample tests
Flame propagation testIEC 60332-1-2 / UL VW-1 / ISO 6722-1Per production batch
Insulation & sheath material physical propertiesNEMA WC 27500 (MIL-DTL-27500) · SAE AS22759Type approval

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

NEMA WC 27500 (MIL-DTL-27500) · SAE AS22759CE · RoHS 2 (2011/65/EU) · REACH

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

M27500-[AWG][Type][Cores][Shield][Jacket] NEMA WC 27500 TEBAOFLEX
Delivery form
Export wooden drums, reels or coils, cut-to-length on request
Packaging
Heat-treated ISPM-15 timber drums or spools with sealed ends
Conductor / colour options
Custom core counts, stripe combinations or cut harnesses on request

Technical documents

Downloads

PDFMIL-27500 Aerospace Multicore Shielded Cable – technical datasheet16 sizes · construction, technical data, approvalsXLSXMIL-27500 spec data (Excel)All 16 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

How do you decode a NEMA WC 27500 (MIL-DTL-27500) part number such as M27500-22TE2T14?
In `M27500-22TE2T14`: `-` indicates MIL-STD-681 Method 1 striped colour coding; `22` = 22 AWG conductor; `TE` = SAE AS22759/16 extruded ETFE primary wire (tin-plated copper, +150 °C); `2` = 2 twisted cores (pair); `T` = single round tinned-copper braid shield (+150 °C); and `14` = white extruded ETFE outer jacket.
What are the most common AS22759 primary wire codes used inside MIL-27500?
`TE` = AS22759/16 (extruded ETFE, tin-Cu, 150 °C); `TG` = AS22759/18 (thin-wall ETFE, tin-Cu, 150 °C); `SB` = AS22759/32 (cross-linked XLETFE, tin-Cu, 150 °C); `SD` = AS22759/34 (dual-wall XLETFE, tin-Cu, 150 °C); `SE` = AS22759/35 (XLETFE, silver-Cu, 200 °C); and `RC` = AS22759/11 (extruded PTFE, silver-Cu, 200 °C).
What is the difference between Jacket Style 06, Style 14 and Style 23?
Style 06 is extruded fluorinated ethylene propylene (FEP, +200 °C, often clear/translucent); Style 14 is extruded ethylene tetrafluoroethylene (ETFE, +150 °C, white laser-markable); and Style 23 is cross-linked XLETFE (+150/+200 °C, white laser-markable with superior scrape and cut-through resistance).
Why do aerospace 22 AWG and 20 AWG wires have slightly larger cross-sections than commercial AWG?
Because SAE AS22759 specifies 19 concentric strands of standard mil-gauge wires (e.g. 22 AWG = 19 strands of 34 AWG = 0.38 mm² vs 0.33 mm² for 7/30 commercial wire), providing higher tensile strength and flex-fatigue life under airframe vibration.

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MIL-27500 Aerospace Multicore Shielded Cable

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