Ground-breaking Aircraft Wiring Repair Product Wins Innovation Award

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New TE Cold-Applied Splice Reduces Aircraft Wiring Repair Time By 70%

Tyco Electronics (TE), one of the leading global providers of engineered electronic components, connectors and network solutions, was recently recognized by the US Naval Air Systems Command with an Innovation Award. The Naval Air Warfare Center Aircraft Division (NAWCAD) Commander’s Awards were established to recognize outstanding teams and individuals that support NAWCAD’s goals and objectives.

The Aircraft Wiring Systems Team, in collaboration with industry partner TE, as well as fleet maintainers, developed an innovative cold-applied splice (CAS) wiring repair product and tooling that reduces aircraft wiring repair time by more than 70 percent. The innovative process also eliminates all the support equipment previously required for legacy repair methods.

Wire splicing, to replace segments of damaged wire or install new segments of wire, is the most common type of repair on wiring systems for all type/model/series aircraft. The man hours and budget savings the new cold-applied splice can provide to both military and commercial aerospace applications are therefore immense.

“This innovation is projected to save 77,000 maintenance-man-hours (MMHRs) per year for the Navy, and over 308,000 MMHRs per year across the [Department of Defense],” said Oliviu Muja, Wiring Systems Branch, Naval Air Systems Command, in the award citation.

Current aircraft are filled with literally miles of wire, which transfer power and signals to and from vital flight critical systems. Damaged or degraded wiring can have an immediate effect on safety-of-flight, combat capability and readiness. The new tool and splice methodology provides a permanent installation with electrical characteristics that either meet or exceed current specification requirements and can be applied to the entire inventory of military and commercial aerospace manned and unmanned vehicles, including Allied and NATO partners.

The cold-applied splice’s one-piece construction offers wire termination, as well as environmental sealing in a single step. Sealing is provided without the need for adhesives, tapes, grommets or other methods traditionally used in aerospace and defense applications. Because no heat is needed, the splice can be applied in potentially hazardous places, such as in fueled aircraft.

For more information on the TE cold-applied splice, contact TE’s Product Information Center at (800) 522-6752. Follow us on Twitter for all the latest product news @TycoElectronics.

TE (logo) and Tyco Electronics are trademarks.

Tyco Electronics Ltd. is a global technology company with fiscal 2010 sales of US $12.1 billion to customers in more than 150 countries. We design, manufacture and market products for customers in a broad array of industries including automotive; data communication systems; consumer electronics; telecommunications; aerospace, defense and marine; medical; energy; and lighting. With approximately 7,000 engineers and worldwide manufacturing, sales and customer service capabilities, we are a recognized leader in many of the industries we serve. More information on TE can be found at

While Tyco Electronics has made every reasonable effort to ensure the accuracy of the information for this product launch, Tyco Electronics does not guarantee that it is error-free, nor does Tyco Electronics make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. Tyco Electronics reserves the right to make any adjustments to the information contained herein at any time without notice. Tyco Electronics expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult Tyco Electronics for the latest dimensions and design specifications.


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DeAnna Halewski
Tyco Electroincs
717.652.0100 ext. 21
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