Sep. 08, 2025
The name aircraft cable can be very confusing, especially if you are a novice. Although the name says aircraft, this wire rope often gets used outside the aerospace industry. Yes, you can use it to hold a plane in position. But you can also use it in boats and docking, securing cargo, stage rigging, and winching, among other things.
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In fact, airplane cable is one of the most used wire ropes around the globe. The global aircraft wire and cable market was worth $1.5 billion in . It is likely to reach $1.9 billion by , at a CAGR of 5.7%, during the forecast period of to .
Chances are you will also use aircraft cable at some point. So, it’s better to know everything you can about it. Let’s start with the basics.
As mentioned before, the name aircraft cable can be misleading. Yes, airline cable gets used on and around airplanes. But it has a lot more to offer when it comes to lifting and rigging applications, even in harsh environments.
Airplane cable is a wire rope consisting steel wires stranded together, usually between 8 and 28. These stands form a strong and flexible airline cable. As a result, they are used in different applications, including control cables, rigging, and suspension systems.
However, it is also important to use high-quality aircraft cable hardware, such as fittings, turnbuckles, shackles, thimbles, and connectors, to ensure reliability and safety during lifting and rigging applications. after all, you don’t want the airline cable to snap, resulting in extensive damage to your cargo, injuries to your crew, and maybe worse.
But most importantly, ensure your airline cable meets the strict industry standards. It should also undergo rigorous testing to be able to withstand the required stress. Also, never cross the working load limit of any cable.
You can find these cables in wing flaps, landing gear, and seat back controls, among other parts of an airplane. But it also gets used outside of the aerospace industry. The cable is popular in heavy-duty applications due to its strength.
The aircraft cable strength is exceptional even when used for strenuous application in harsher weather conditions. Usually, the galvanized steel aircraft cable strength is higher than that of stainless steel.
Aircraft cable wires have to endure harsh environments, which can lead to corrosion and wear over time. Different finishes are applied to the cable surfaces to protect them and extend their lifespan. One common finish is galvanization, where the cable is coated with a layer of zinc to prevent corrosion.
In most cases, you should coat the aircraft cable hardware, such as turnbuckles and shackles, with similar finishes to protect against corrosion and wear. Choosing the right finish for aircraft cable wires and hardware is critical to maintaining the integrity and safety of the aircraft and your rigging applications.
Most aircraft cable suppliers will sell these aircraft cable wires in four finishes. They are galvanized cable, stainless steel cable (also called aircraft steel cable), vinyl-coated galvanized rope, and vinyl-coated stainless steel rope.
This cable is stronger than stainless steel airplane cable. It offers moderate corrosion resistance but remains ductile for a long time.
Although a little less strong than galvanized airplane cable, it offers excellent corrosion resistance. These cables are more suited for marine applications, where they get exposed to saltwater and high humidity.
This cable offers durability, flexibility, and moderate resistance to corrosion. It is best suited for indoor applications.
As you can imagine, this cable provides additional corrosion and abrasion resistance. It also offers high flexibility but less aircraft cable strength than its galvanized variant.
Unlike the name suggests, aircraft cable gets used in applications outside of the aerospace industry. And the exceptional aircraft cable strength makes it ideal for strenuous applications, especially in harsh environments. Here are a few common uses.
Stainless steel aircraft cable gets used in moving and shipping aircraft. On the other hand, galvanized cable is found in airplane seats, landing gear, and wing flaps.
Stainless steel aircraft cable is an excellent choice for all docking and boat applications. It is flexible and resistant to corrosion.
Airplane cable often gets used in fitness equipment such as weight machines. You can use either stainless steel or galvanized cables for this application.
Garage door pulleys (raising and lowering mechanisms) often use aircraft cable due to their strength.
Galvanized aircraft cables often get used to secure cargo, especially heavy shipments. The stainless steel cable offers good corrosion resistance in saltwater and high humidity.
You will also see airplane cables in stage rigging. You can use them to suspend and raise lighting, handle curtains, and even move backdrops.
Aircraft cable offers strength and flexibility, making it suitable for almost all rigging, overhead lifting, and hoisting applications. You can use either stainless or galvanized steel cable based on your application.
Usually, Ziplines are used for recreational purposes. Both stainless steel and galvanized cables get used as Ziplines. They are strong enough to support the weight of a person.
Although aircraft cable is durable and corrosion-resistant, it needs regular maintenance. Maintenance increases its lifespan and reduces the risk of potential accidents. Aircraft steel cable is an essential component of any aircraft, and its safety and integrity cannot be compromised. It is vital to inspect the aircraft cable wire regularly to ensure that it is in good condition and capable of performing its intended function.
So, be sure to inspect the cable before each use. It’s a simple visual inspection. Check the aircraft cable for broken strands. Check even the hidden parts of the cable for potential damage. These are visible signs of damage, such as kinks, frayed strands, or corrosion. These can weaken the aircraft steel cable and reduce its strength, so any damaged areas should be replaced or repaired immediately.
You can run a cotton cloth over the length of the wires. It’s the easiest and best way to check it for broken strands. If the cable has broken strands, the cloth will get snagged. Make sure to wear protective gloves when inspecting the aircraft cable.
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Next, check the cable’s tension by applying a load and measuring the deflection. An aircraft cable that is too loose or too tight can cause problems. Finally, inspect the aircraft cable hardware, such as fittings and turnbuckles, for signs of wear or damage. These parts are crucial for keeping the cable securely in place. So, if there are any issues, address them promptly.
One more thing you need to know is how to swage aircraft cable. Swaging is a technique used to attach aircraft cable hardware securely. Swaging helps prevent the wire rope from fraying and improves its straightness. Also, the smoother end can easily slide over pulleys and inside sleeves.
Swaging involves using special tools to compress the cable and the hardware together, creating a permanent and robust connection. There are different tools available to swage cables correctly. The most cost-effective and easy-to-use tools are manual plier types. But you can also get battery-operated hydraulic swaging tools.
Remember, swaging is a necessary part of putting together aircraft cable hardware. However, you must always follow the manufacturer’s instructions and safety guidelines. Moreover, ensure that your cable and hardware are compatible for the best results. In case of any doubts, contact your aircraft cable supplier to find a suitable tool.
As you already know, aircraft steel cable gets used in strenuous applications under harsh weather conditions. It’s going to be a significant investment. You will need to find a trusted aircraft cable supplier who can help you make the right purchase without breaking the bank.
When looking for an aircraft cable supplier, consider the following factors.
You can use aircraft cable for a variety of applications. It is flexible, strong, and corrosion-resistant. Hopefully, this post will help you understand what it is, where to use it, how to swage aircraft cable, and how to find a reliable aircraft cable supplier.
Are you looking for high-quality aircraft cable? You have come to the right place. Elite Sales is a leading supplier in Houston, Tampa, Miami, and Dyer. With a well-stocked inventory, you can readily find the airplane cable you need along with other industrial hardware.
In the business of flight, manufacturers can’t rely on subpar components. Everything on your aircraft needs to work the first time every time. That’s why Orscheln Products creates aircraft cable assemblies trusted every day by OEMs all over the world.
Common aircraft cable assemblies we create are used in failsafe systems as well as mechanical controls. We create solutions for controls, escape slides, and even emergency Ram Air deployment. In emergencies, failure is not an option. When it matters most, tier 1 and 2 manufacturers trust Orscheln to design, certify and produce solutions that perform under pressure.
At Orscheln, custom doesn’t have to mean complicated. When we engineer aerospace solutions, we include your design team in every detail of the product. A great way to start the conversation is by understanding what we can do. Below you will find a table to help you understand our capabilities.
Our most popular application in the aerospace industry is our conventional push-pull cables. On the surface, these cables look like any other control cable. However, our push-pull cables are anything but regular. Each series of cable is customizable with standard ends depending on the application. Additionally, these are aerospace-specific solutions designed to meet your demands and industry safety requirements.
Use this table to understand what series of push-pull cables might be right for your specifications.
Conventional Push-Pull Cables: Aircraft/Aerospace Applications* 3 Series 4 Series 6 Series Size 3/32″ Nominal 1/8″ Nominal 3/16″ Nominal Threaded End Rods 10-32 UNF 1/4-28 UNF 5/16-UNF Stroke Travel Inch TensionPull CompressionPush TensionPull Compression Push Tension Pull Compression Push 1 90 60 185 125 260 175 2 90 45 185 90 260 150 3 90 35 185 75 260 130 4 90 30 185 65 260 115 Min Bend Radius Inches 3 4 6 Temperature Range** Standard: -55°C to +107°C High Efficiency: -55°C to +163°CConventional push-pull cables for Aerospace/Aircraft are different in design, construction, materials, and manufacturing than Orscheln HP Cables for industrial use. If you don’t see your desired spec, talk to an engineer for higher temperature ranges amongst other custom options. Depending on the application, your needs may be better suited by our ball-bearing cable.
Orscheln’s ball-bearing cables essentially consist of a flexible linear ball bearing that transfers push-pull motion from one point to another. This unique design allows for the transmission of movement maximizing efficiency and minimizing lost motion. It’s easy to think of this as a strand of ball bearings in a cage instead of a collection of strands of metal.
Ball-bearing cables are very different from conventional push-pull cables. So they can’t be treated the same way. It’s important to keep in mind that when a ball-bearing cable is bent, the three internal rails will form concentric arcs. This means that either the outer rail must increase in length, or the inside outer rail must shorten due to the difference in radii.
Our engineers keep this in mind by implementing an internal anchoring system. This anchoring system maintains the structural integrity of the entire cable, but it means that these cables can’t be used the same way conventional cables can be. See the table below for the capabilities of our ball-bearing aircraft cable assemblies.
Maximum Recommended Input Loads Compression: Type 58 Type 78 Type 98 Stroke 1″— 4″ 50 lbs. 200 lbs. 400 lbs. Stroke 5″— 6″ 100 lbs. 250 lbs. Stroke 7″— 8″ 40 lbs. 100 lbs. Tension: Stroke 1″—8″ 100 lbs. 300 lbs. 500 lbs. Minimum Recommended Bend Radius Occasional Cycling 3.50 in. 4.00 in. 5.00 in. Continuous Cycling 7.00 in. 12.00 in. 15.00 in. Elastic Stretch Push or PUll, Per Foot by 20 lbs. of Input Load 0. in. 0. in. 0. in. Temperature Range with Plastic Cover* -55℃ to +105℃ Temperature Range without Plastic Cover -55℃ to +315℃ Maximum Overall Length** 30 ft. 65 ft. 65 ft.The structure of these cables may limit their usage. But ball bearing cables are second to none due to their efficiency, durability, and the lowest linear stretch of any aircraft cable assemblies. Higher temperature covers, longer lengths, and custom bends over 180 degrees are all solutions you can discuss when considering ball-bearing cables. There are very few limitations when you design your solution with Orscheln.
Trusted solutions don’t just happen overnight. When building your aircraft cable assemblies with Orscheln, we take the time to produce the best product possible for various aircraft applications. We discuss timelines based on your specific needs. Here is how our engineers turn your needs into industry-leading solutions.
Everything we engineer starts with a design. This is where we ask a lot of questions and start envisioning solutions. Our engineers begin by analyzing CAD models and blueprints of your aircraft. Once we have the CAD files, we can go over possible solutions and build models to test prototypes against.
This is our engineers’ favorite part of the process. When we build your prototypes, we keep your usage, requirements, and environmental factors in mind. For example, during the testing stage, we may find that ball-bearing cables may be better suited for your application than push-pull cables. Your engineer will walk you through as much of this process as you want to be involved in. Some of our clients love to know about the science behind their solutions, while others just need to know their product works.
Every single aircraft cable assembly that we create goes through rigorous testing and stringent certifications before we put it into production. We meet all requirements for governing organizations such as the FAA, and can meet specific standards such as RTCA DO-160 and MIL-STD810 along with any special requirements your company may have as well. Below are our current certifications.
These are the industry standards you should ask any parts manufacturer about. The FAA and PMA-approved parts are set forth to ensure product quality and reliability. As well as sustainability and corporate responsibility. For more information about compliance and certifications, contact us with any questions you may have.
The final step of our production process is to produce the finished solution. Our facilities are capable of mass-produced and small-batch solutions. We monitor production quality with the first and last examples for every hour lot to ensure quality down to the micron. Proof loads can be added to each part if required as well. If you need to adjust your solution for any reason, we repeat the entire process for any changes to ensure quality and compliance. First Article Inspections are available as well. The flexibility and reliability of our production solutions are the reason OEMs continue to trust Orscheln with their solutions.
Our capabilities include meeting more than just technical standards. In addition to maintaining an FAA PMA-approved QMS. Orscheln follows the APQP product development process as part of our standard engineering/product development procedure. Orscheln Products APQP development process incorporates best practices including design and process FMEAs, design reviews, validation testing, control plans, and PPAPs. This demonstrates our commitment to 100% customer satisfaction the first time, every time.
Since Orscheln has been providing reliable solutions. We bring decades of experience to every solution our engineers create. That means your solution comes from our history and some of the greatest minds in the industry learning and building together to innovate solutions for the future of transportation on land, sea, air, and even space.
Orscheln remains trusted by tier 1 and tier 2 public, private, Military, and commercial aircraft manufacturers. But as space flight emerges, our engineers are creating solutions for the final frontier. While our solutions are continually evolving within the atmosphere, our engineers are designing solutions for private, commercial, Military, and exploratory spacecraft.
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