Ultra-Lightweight Space Wire Meeting NASA and ESA Standards
LEW Lightweight Electrical Wire: Maximum Performance, Minimum Mass
Gore LEW-series lightweight electrical wires combine radiation-hardened ePTFE insulation with mass-optimized conductor construction, meeting NASA and ESA outgassing standards for satellite applications where every gram of harness weight carries a real cost.
LEW-series lightweight electrical wires with radiation-hardened ePTFE insulation, meeting NASA and ESA outgassing standards for satellite applications. The LEW series is purpose-built for spacecraft harnesses where low weight and small diameter are as important as electrical performance and environmental qualification.
Why Choose Gore LEW Space Cables?
Mass Savings That Translate to Mission Capability
Spacecraft harnesses can account for 5–10% of total spacecraft mass. LEW's lightweight construction — achieved through fine conductor stranding, thin ePTFE wall insulation, and low-density materials — reduces harness mass by 30–50% compared to conventional space-grade wire of equivalent current capacity. On a communications satellite, this mass saving translates directly to additional payload capacity or fuel for extended mission life.
Radiation Hardening for Long Mission Lifetimes
Conventional polymer insulations become brittle and crack under accumulated radiation dose, creating short circuits and harness failures in long-duration missions. Gore's ePTFE insulation is inherently radiation-resistant, maintaining its mechanical and electrical properties through the total ionizing dose levels encountered in 15-year GEO satellite missions and extended deep-space missions.
Dual NASA/ESA Outgassing Qualification
Meeting both NASA outgassing requirements (ASTM E595) and ESA requirements (ECSS-Q-ST-70-02) provides maximum procurement flexibility for international programs. LEW materials have been characterized for total mass loss (TML) and collected volatile condensable material (CVCM) values that satisfy the most demanding contamination control specifications.
Technical Specifications
- Insulation
- Radiation-hardened ePTFE
- Conductor
- Silver-plated copper, fine stranded
- Conductor Sizes
- 30–22 AWG (application dependent)
- Operating Temperature
- -180°C to +200°C
- Outgassing (NASA)
- ASTM E595: TML ≤1.0%, CVCM ≤0.1%
- Outgassing (ESA)
- ECSS-Q-ST-70-02 compliant
- Voltage Rating
- 300 V (application dependent)
Applications
- General-purpose signal wiring throughout spacecraft harness
- Attitude and orbit control system (AOCS) sensor wiring
- Thermal control heater and temperature sensor circuits
- Battery management system wiring in power subsystem
- Telemetry, tracking and command (TT&C) subsystem wiring
- Payload instrument internal low-current signal wiring
Industries Served
Frequently Asked Questions
What is the weight saving of LEW compared to standard MIL-W-22759 wire?
LEW series cables achieve significant weight reductions compared to standard MIL-W-22759/32 or equivalent. The exact saving depends on gauge and configuration — Gore's technical data sheets provide weight-per-meter figures for direct comparison with your existing wire specification.
Is LEW wire suitable for use in crewed spacecraft?
LEW wire's low-outgassing and flame-retardant properties make it suitable for habitable spacecraft environments, subject to the specific crewed spacecraft certification requirements of the applicable program. Contact RSTECH to discuss certification documentation support.
Can LEW wire be procured with full material traceability for flight use?
Yes. RSTECH Electronics supplies LEW wire with full material traceability documentation including material certifications, lot traceability, and test reports. This documentation package satisfies the source control requirements of typical spacecraft hardware procurement contracts.
What connector termination options are available for LEW wire?
LEW wire can be terminated to any space-qualified connector system including Micro-D, D-Sub, circular MIL-DTL-38999, and custom interfaces. RSTECH can source both raw wire and terminated harness assemblies, working with qualified space harness manufacturers in Israel.
Ready to source LEW Space Cables in Israel?
Contact RSTECH Electronics — your authorized Gore representative in Israel.