Pelican Wire Continues to Support Mission-Critical Applications at all Altitudes
Operating at 35,000 feet, modern aircraft must manage extreme environmental conditions, including sub-zero temperatures that can jeopardize onboard fluid systems. Pelican Wire plays a vital role in maintaining functionality in these systems by supplying ultra-fine gauge heating wire assemblies designed for thermal management within aircraft hose and tubing systems.
One such engineered wire solution includes:
- Conductor Configuration: 2 strands of 42 AWG Nichrome 60 (0.0025″)
- Core: Glass fiber wound core for mechanical strength and dielectric stability
- Resistance: 95 Ohms/ft ±4%
- Insulation: 0.005″ Polyimide (Kapton®) tape wrap
- Nominal Finished Diameter: 0.033″ ±0.002″
Application: Heated Hose Assemblies in Aerospace Environments
These heating wires are designed for use in aerospace fluid systems, where they are embedded within or wrapped around flexible hoses that transport water and other fluids throughout the aircraft. Without thermal regulation, these systems would be vulnerable to freezing at altitude, threatening both safety and operational integrity.
The wire’s construction is optimized for:
- Uniform resistive heating over long runs
- High dielectric performance under thermal cycling
- Flexibility and minimal added weight—critical for aerospace design
- Stability under vibration, pressure changes, and fluctuating ambient conditions
Specialized Fine Wire Fabrication
Pelican Wire’s ability to consistently produce ultra-fine resistance wires in gauges as small as 42 AWG—while maintaining tight resistance tolerances and insulation integrity—is a testament to our advanced manufacturing capabilities. Our experience with small-gauge materials, complex multi-strand builds, and high-performance insulation systems makes us a valued partner in aerospace and other high-reliability industries.
This solution is part of a larger family of heating wires we provide to thermal systems manufacturers across industries. Whether the application requires 31 AWG, 34 AWG, or even finer, Pelican Wire is uniquely positioned to engineer and deliver high-precision resistance wire products at scale.
Looking for heating wire solutions for aerospace or other critical fluid management systems?