IN2Connect with Calmont Wire and Cable Alresford, Hampshire, UK 11/06/04

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Lightweight signal cables made with Tefzel® and DuPont� Aracon® Metal-clad fibres save space in space.

Metal-clad fibres deliver high-value weight savings and high-fidelity signal transmission in space satellites for the US anti-missile defense system known as SBIRS (space-based infrared system).

The data transmission cables contain shielded single, paired and multiple conductors, and each conductor is insulated with just 0.003" to 0.015" of Tefzel®, depending on the conductor gauge. Tefzel® provides flex endurance, abrasion resistance and radiation resistance.

The cable harness for the SBIRS antenna weighs about 3.5 pounds less than equivalent cables using metal braid and alternative insulation and jacketing materials. With payload weight valued at £50,000 per pound, the lightweight cable saves the SBIRS program £53,000 per satellite after accounting for the additional cost of the Aracon® braid compared with metal.

Calmont has developed specialized manufacturing processes and controls to produce high quality custom cables incorporating these special materials that offer outstanding dielectric and mechanical properties for lightweight insulation in satellite cabling; and in the case of Aracon®, a metal-clad fibre in the form of woven braid provides effective, flexible EMI shielding at much lighter weight than metal braid.

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Bob Hart
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