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Product

M81044 dual-wall XL-polyalkene/PVDF aerospace wireSAE AS81044 / MIL-DTL-81044−65 °C to +150 °CDual-Wall XL-Polyalkene / PVDF

M81044 MIL-DTL-81044 Dual-Wall Cross-LinkedPVDF/PolyalkeneSAE AS81044 / MIL-DTL-81044 600 V −65…+150 °C dual-wall e-beam cross-linked polyalkene

Aerospace, defence and professional motorsport dual-wall hook-up wire (M81044) built to SAE AS81044 / MIL-DTL-81044 (/6, /9, /12, /13), combining an electron-beam cross-linked polyalkene primary dielectric with a tough, clear or pigmented cross-linked.

Flame-retardant
Ozone, UV & moisture
Oil-resistant
Order designation
M81044/12-22-*
AWG & wall
22 AWG Light
Nominal OD
1.09 (0.043")
Max DC R20
53.1 Ω/km
Max weight
3.87 kg/km
All sizes (12)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Voltage rating
600 Vrms
M81044/12 & /13 Light · /6 & /9 Normal
Temperature
−65 to +150 °C
E-beam cross-linked thermoset
Size range
30 AWG to 4 AWG
19-strand & 37-strand concentric
Conductor
SnCu or AgCu
Tinned (/9, /12) or Silver (/6, /13)
Dual-wall sys
XL-Polyalk+PVDF
Low ε_r inner + cut-resistant skin
Fluid resistance
Skydrol & JP-8
Jet fuel, hydraulic & de-icing fluids

Typical values for this cable type, based on SAE AS81044 / MIL-DTL-81044 (M81044/6, /9, /12, /13) — confirmed in the datasheet and quotation for your order.

Application fit

Is M81044 right for your machine?

The industry-standard dual-wall wire for military avionics bays, ground combat vehicles, naval weapon consoles, and Formula/LMP motorsport looms.

Switchgear & control cabinet wiring

Suitable

M81044/12 (tinned) and M81044/13 (silver) thin-wall builds pack densely into MIL-DTL-38999 circular connectors.

Motor stator, traction & converter leads

Suitable

Outer cross-linked PVDF jacket resists pinch cut-through, potting compounds, Skydrol hydraulic fluid and JP-8 fuel.

Furnace, kiln & high-temp zone

Suitable

Radiation cross-linking prevents melting or soldering-iron shrinkback and supports −65 °C to +150 °C continuous service.

Fixed installation

Suitable

Forms the core component of MIL-DTL-55021 twisted pairs/triads and MIL-DTL-27500 shielded aerospace harness cables.

Typical machinesMilitary & Commercial Avionics Rack & Cockpit HarnessesArmoured Ground Vehicles, Radar Shelters & Missile LaunchersFormula, Le Mans Prototype & Rally Motorsport Engine LoomsNaval Shipboard Combat Systems & Submarine ConsolesHigh-Reliability Downhole & Industrial Sensor Instrumentation

Construction

Layer by layer

Representative M81044/12 (Light-Weight Tinned) or M81044/9 (Normal-Weight Tinned) build: 19-strand concentric tinned copper (ASTM B33) or silver-plated copper (ASTM B298, /6 & /13) conductor + extruded e-beam cross-linked polyalkene primary dielectric + extruded e-beam cross-linked polyvinylidene fluoride (XL-PVDF) outer jacket.

123
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
119-strand or 37-strand tinned (/9, /12) or silver-plated (/6, /13) copperPrecision concentric-lay stranded copper (no bunching): tinned copper for −65 °C to +150 °C general defence/motorsport use (/9, /12) or silver-plated copper (/6, /13) for lower HF resistance and solderabilityGuarantees uniform circular concentricity for ultra-thin dual-wall extrusion and reliable MIL-C-39029 contact crimping
2E-beam cross-linked polyalkene primary dielectricHigh-purity polyalkene inner wall thermoset by high-energy electron-beam irradiationDelivers low dielectric constant (ε_r ≈ 2.3), high insulation resistance and zero melt flow at +300 °C overload
3E-beam cross-linked PVDF (Polyvinylidene Fluoride) outer jacketHard, tough radiation-crosslinked fluoropolymer outer jacket bonded over the polyalkene coreProvides superior abrasion, cut-through, flame (FAR 25.853 / MIL-DTL-81044 vertical burn) and aerospace fluid resistance

M81044/12 (Light-Weight 600 V, Tinned Cu) & M81044/13 (Silver Cu)

0.19 mm (7.5 mil) nominal total dual-wall thickness (30–12 AWG) for high-density avionics, MIL-DTL-55021 pairs and motorsport harnesses

M81044/9 (Normal-Weight 600 V, Tinned Cu) & M81044/6 (Silver Cu)

0.28 mm (11 mil) medium dual-wall thickness (26–4 AWG) for exposed airframe bays, ground vehicle turrets and power distribution

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on SAE AS81044 / MIL-DTL-81044 (M81044/6, /9, /12, /13). Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage
600 Vrms (DC and AC up to 2,000 Hz)
Dielectric withstand (wet)
2.5 kVrms immersion test (100 % routine)
High-frequency spark test
6.0 kVrms in-line dry spark test (100 % of length)
Insulation resistance
≥ 5,000 MΩ·km at +20 °C

Thermal

Operating temperature
−65 °C to +150 °C continuous
Short-term / solder resistance
+300 °C heat aging / zero melt under hot soldering iron

Mechanical

Slash sheets
M81044/12 (Light SnCu) · M81044/13 (Light AgCu) · M81044/9 (Normal SnCu) · M81044/6 (Normal AgCu)
Size range
30 AWG to 12 AWG (M81044/12 & /13) · 26 AWG to 4 AWG (M81044/9 & /6)
Min. bend radius
3 × OD fixed · 5 × OD harness flexing

Resistance

Aerospace fluids
Resistant to MIL-PRF-5606 / Skydrol hydraulic fluid, JP-8 jet fuel, MIL-PRF-23699 lube oil & de-icing fluid
Flammability
Passes MIL-DTL-81044 / SAE AS4373 60° & vertical self-extinguishing flame test

Reference standards

Governing specification
SAE AS81044 / MIL-DTL-81044
Next-level cable standards
Used as primary core in MIL-DTL-55021 & NEMA WC 27500 (MIL-DTL-27500)

Identification

Colour coding
MIL-STD-681 10 base colours (0 Black to 9 White) + 1 or 2 spiral stripes
Surface marking
Hot-stamp or UV laser wire identification per SAE AS50881
Customs tariff (HS)
8544.49

Sizes

12 standard M81044/12 (Light-Weight) & M81044/9 (Normal-Weight) aerospace hook-up wires

SAE AS81044 / MIL-DTL-81044 dimensions, concentric stranding, finished OD, max DC resistance and nominal weight.

MIL part number, AWG, stranding, OD & weight
MIL Part NumberSize (AWG)Stranding
(N × AWG)		Cond. OD
mm		Nom. OD
mm (in.)		Max R20
Ω/km		Max Weight
kg/km		Enquiry
M81044/12 Light-Weight Dual-Wall Tinned Copper (30 AWG to 12 AWG, 600 V)
M81044/12-28-*28 AWG Light7 × 36 AWG SnCu0.380.69 (0.027")227.01.15
M81044/12-26-*26 AWG Light19 × 38 AWG SnCu0.480.84 (0.033")135.51.79
M81044/12-24-*24 AWG Light19 × 36 AWG SnCu0.610.97 (0.038")86.02.68
M81044/12-22-*22 AWG Light19 × 34 AWG SnCu0.761.09 (0.043")53.13.87
M81044/12-20-*20 AWG Light19 × 32 AWG SnCu0.971.27 (0.050")32.05.80
M81044/12-18-*18 AWG Light19 × 30 AWG SnCu1.221.52 (0.060")20.48.78
M81044/12-16-*16 AWG Light19 × 29 AWG SnCu1.371.73 (0.068")15.811.16
M81044/12-12-*12 AWG Light37 × 28 AWG SnCu2.262.69 (0.106")6.828.30
M81044/9 Normal-Weight Dual-Wall Tinned Copper (24 AWG to 8 AWG, 600 V)
M81044/9-22-*22 AWG Normal19 × 34 AWG SnCu0.761.37 (0.054")53.14.76
M81044/9-20-*20 AWG Normal19 × 32 AWG SnCu0.971.57 (0.062")32.06.85
M81044/9-16-*16 AWG Normal19 × 29 AWG SnCu1.372.06 (0.081")15.812.65
M81044/9-8-*8 AWG Normal133 × 29 AWG SnCu4.245.23 (0.206")2.387.80
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Replace '*' in the MIL part number with the MIL-STD-681 colour code (e.g., -9 for White, -0 for Black, -92 for White with Red stripe). Silver-plated M81044/13 and M81044/6 have identical dimensions.

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
100 % 6.0 kVrms impulse/spark test & 2.5 kVrms water immersion testVerify zero pinholes across both the inner XL-polyalkene and outer XL-PVDF walls100 % of manufactured length
Concentricity (≥ 70 %), OD tolerance & conductor DC resistanceLaser micrometer wall-ratio audit and ASTM B33/B298 stranding resistance checkEvery production spool
Sample tests
+300 °C cross-link wrap test, −65 °C cold bend & Skydrol fluid immersionVerify electron-beam cross-linking degree, cold flexibility and fluid swell resistanceLot qualification

Inspection certificate

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

Product approvals

SAE AS81044 / MIL-DTL-81044 (/6, /9, /12, /13) CompliantSAE AS50881 Aerospace Harness Selection Compliant

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

MIL-STD-681 Solid Colour / Helical Stripes & Optional UV Laser Harness Code
Delivery form
500 ft, 1,000 ft & 5,000 ft spools in all 10 MIL-STD-681 base colours + stripes
Harness twisting
Available twisted/shielded to MIL-DTL-55021 or MIL-DTL-27500
Lead time
Stock to 3 weeks ex-works

Technical documents

Downloads

PDFM81044 MIL-DTL-81044 Dual-Wall Cross-LinkedPVDF/Polyalkene – technical datasheet12 sizes · construction, technical data, approvalsXLSXM81044 spec data (Excel)All 12 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.

Why does MIL-DTL-81044 use a two-layer (XL-polyalkene + XL-PVDF) insulation instead of a single polymer wall?
No single polymer combines ultra-low dielectric constant with extreme mechanical hardness. In M81044, the inner electron-beam cross-linked polyalkene layer provides outstanding electrical properties (low dielectric constant ε_r ≈ 2.3, high insulation resistance, and flexibility), while the thin outer cross-linked PVDF layer acts as a hard, slick mechanical shell that resists sharp chassis edges, connector backshell pinch, and aggressive aviation fluids.
What is the difference between M81044/12, M81044/13, M81044/9 and M81044/6?
M81044/12 and M81044/13 are Light-Weight (thin-wall ~0.19 mm) 600 V wires for compact avionics, motorsport looms, and high-density circular connectors (/12 uses tinned copper; /13 uses silver-plated copper). M81044/9 (tinned copper) and M81044/6 (silver-plated copper) are Normal-Weight (~0.28 mm wall) 600 V wires for open airframe routing and heavier mechanical abuse.
Why is M81044/12 (Spec 44) the universal standard for Formula and endurance motorsport wiring looms?
Motorsport harnesses packed around +130 °C engine blocks and carbon-fibre tubs require minimum weight, small bundle diameter for concentric twisting with DR-25 elastomer boots, immunity to fuel/brake fluid/gear oil, and high cut-through strength against vibration. M81044/12 meets every one of those criteria at a fraction of the cost of pure fluoropolymer space wires.
How does M81044 relate to MIL-DTL-55021 and MIL-DTL-27500?
M81044 is the single-core building block. When two or three M81044/12 or /9 single cores are precision-twisted into pairs or triplets (unshielded or shielded) for internal electronics racks, they are governed by MIL-DTL-55021; when cabled and jacketed into heavy airframe multi-core cables, they are governed by NEMA WC 27500 (MIL-DTL-27500).

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M81044 MIL-DTL-81044 Dual-Wall Cross-LinkedPVDF/Polyalkene

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