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For one, the C7 core comprises seven (or more, depending on cable diameter) 3.2-mm/0.13-inch diameter strands of aerospace-grade carbon fiber pultruded with Fortron PPS (polyphenylene sulfide) from Celanese. The core is isolated from direct contact with the cable’s aluminum conductor strands by an overwrap of polyetheretherketone (PEEK), which protects the aluminum from galvanic corrosion and prevents abrasion of the core

For all these applications, the same challenges requiring solutions arise. To begin with, rising raw material prices have been triggering a strong trend towards cutting down the material input as far as possible throughout the entire manufacturing process. In addition, with space being a restriction, the allowable amount and volume of conductors to be incorporated in any of the above devices is limited. At the same time, the processes, which are controlled by means of electric signals, are growing more and more diverse so that an increasing number of functions has to be taken care of by each conductor. In particular when it comes to building automobiles, aircraft or aerospace vehicles, exceptional weight efficiency is requested nowadays in order to minimize fuel consumption. The flexibility of a strand constitutes another property that can only be accomplished by increasing the number of single wires used. Just take the following example: A strand composed of 19 wires with a diameter of 0.20 mm each will end up having the same cross-section (0.6 mm²) as another strand made up of 850 wires with a diameter of 0.03 mm each, with the flexibility of the latter being significantly higher.

In an attempt to reduce costs and cut emissions, manufacturers are increasingly turning to energy efficient technologies. Almost two-thirds of companies surveyed planned to increase investment in energy management during the next 12 months, in areas such as renewable and self-generation technologies. The aerospace industry leads the way, with more than two-thirds investing in energy efficient technologies, compared with 41 per cent in metals and aggregates.