Aerospace Cable Assemblies & Aircraft Cable Manufacturing

Wire rope has an abundance of uses in the aerospace industry at every level. Cranes that assist in aircraft construction use robust steel cables to lift and lower heavy parts. Planes use aerospace wire and aircraft cables internally, specifically Bowden push-pull cables, to connect the pedals and levers within the cockpit. The aerospace industry uses wire ropes and cables as shock vibration absorbers, especially in military jets.

In fact, the aerospace industry makes so much use of wire rope and aircraft cable assemblies that this type of cable is now usually referred to as aircraft cable even when it is not being used for flight controls.

The aerospace industry uses wire rope because it is strong, reliable, and able to withstand high amounts of force and pressure, such as when it is thousands of feet in the air. These cables also need to be corrosion- and heat-resistant.

Bowden push-pull cables are used because they help actuate motion and force between the cowl flaps, throttle, propeller pitch, and other aircraft areas. Lexco Cable wire ropes are a trusted choice because they are safe, adaptable, and built for demanding aerospace environments.

Aircraft cable is a type of wire rope designed with tighter tolerances, higher flexibility, and smoother finishes than standard wire rope. It is commonly used in aerospace applications where precision, reliability, and consistent performance are critical, even outside of flight control systems.

Custom wire rope assemblies are used across aerospace applications including seat adjustment systems, cargo handling mechanisms, access panels, unmanned aerial vehicles, flight simulators, and maintenance equipment such as lifting slings. Many of these applications require highly specific configurations and performance characteristics.

Lexco Cable is ISO 9001-compliant and manufactures non-flight critical aerospace assemblies using MIL-DTL-83420 aircraft cable. Lexco can provide AS9102 First Article Inspection reporting, and DFARS compliance when required. These standards ensure consistent quality, traceability, and regulatory alignment for aerospace projects.

AS9102 First Article Inspection is a detailed validation process used in aerospace manufacturing to confirm that a part meets all engineering and design specifications before full production. This includes dimensional measurements and material certifications. AS9102 documents proof of quality and is often required by aerospace manufacturers and contractors at the time of first article.

Aerospace wire rope assemblies are typically made from stainless steel for corrosion resistance. MIL-DTL-83420 Composition B aircraft cable is made from type 302/304 stainless steel. Aircraft cable fittings, such as MS20664, MS20667, MS20668, MS21259, and MS21260, are made from SS303se or SS304, while thimbles, including AN100 and AN111, are made from SS304. The cylindrical terminal BACT14A is SS303se or SS304. Plain balls per NAS494 or BACT14B are SS303se or SS304. Strap forks NAS1494-K and strap eyes NAS1494-E are SS304. Material selection depends on the application, environmental exposure, and required performance.

Wire rope assemblies used in aerospace applications are often swaged per MIL-STD-781 and pull tested or proof loaded per MIL-DTL-5688 to verify strength and performance under load. These tests help ensure the assembly will perform reliably under real-world operating conditions.

Bowden cables are flexible push-pull controls used to transmit force or motion between components. In aircraft systems, they are commonly used for seat adjustments and to connect cockpit controls to mechanical functions such as throttle, flaps, and propeller pitch due to their flexibility and reliability.

Yes. Lexco Cable specializes in custom cable assemblies built to exact specifications. This includes prototyping, engineering support, and production of assemblies tailored to unique aerospace applications, ensuring precise fit and performance.

Wire rope assemblies are essential in aircraft maintenance and ground operations for lifting, securing, and transporting components. This includes lifting slings for mechanics, cargo handling systems, and ground support equipment used in aircraft servicing.

Yes. Lexco Cable has experience supporting advanced aerospace projects, including assemblies designed for specialized missions. Their expertise allows them to meet unique performance requirements, including controlled failure points and precision-engineered cable systems.