M16878/13 Thin-Wall Mil-Spec Hook-Up Wire 250V for Avionics & Precision

Product Overview

The M16878/13 (MIL-DTL-16878/13, NEMA HP-4 Type KT) is a thin-wall Mil-Spec hook-up wire featuring silver-plated copper conductors, engineered for 250V low-voltage signal and control circuits where minimal weight and compact routing are critical. The 0.006-inch thin-wall FEP insulation reduces overall wire diameter and harness weight by up to 25% compared to medium-wall alternatives, making it an ideal choice for avionics bays, satellite payloads, and space-constrained electronic assemblies. Silver-plated copper conductors deliver superior conductivity, excellent solderability, and reliable oxidation resistance — essential for high-reliability signal transmission in aerospace, defense, and precision instrumentation applications.

Key Features and Benefits

250V Thin-Wall Design: 0.006" wall thickness minimizes OD and weight, enabling dense wire bundling in tight avionics and instrument panel layouts.

Silver-Plated Copper Conductors: Combines copper's high conductivity with silver's corrosion resistance and oxidation stability, ensuring low contact resistance and dependable terminations over the wire's service life.

Low Dielectric Loss: FEP's inherently low dielectric constant preserves signal fidelity in precision measurement, data transmission, and high-frequency signal circuits.

-60°C to +200°C Operating Range: Silver-plated conductors maintain full performance across extreme temperature cycling — from high-altitude cold to equipment bay heat.

Self-Extinguishing & Low Smoke: FEP insulation meets stringent aerospace and defense fire safety standards with minimal smoke and toxic gas emission during combustion.

Moisture-Proof Seamless Extrusion: The extruded FEP barrier blocks moisture ingress, protecting conductor integrity in high-humidity or condensation-prone environments.

Technical Specifications

Extensive Size and Dimension Chart

Target Industries and Equipment

Avionics & Flight Control Systems: Signal and control wiring in aircraft instrument panels, flight computers, and avionics bays where every gram of weight reduction matters.

Satellite & Spacecraft Electronics: Internal harness wiring for satellite payloads and space exploration equipment where launch mass directly impacts mission economics.

Precision Test & Measurement Instruments: Hook-up wiring for oscilloscopes, spectrum analyzers, and lab-grade measurement devices requiring low signal attenuation.

Medical Diagnostic Equipment: Low-voltage internal connections for patient monitors, imaging systems, and portable diagnostic tools where material reliability is paramount.

Telecom & Data Backplanes: Signal routing in communication modules and data transmission infrastructure where low dielectric loss preserves signal integrity.

Automotive & EV Sensor Networks: Sensor harnesses, ECU interconnects, and battery management system wiring in tight engine compartments and chassis cavities.

Frequently Asked Questions (FAQ)

Why use silver-plated copper instead of tin-plated for this M16878/13 wire
Silver-plated copper offers higher conductivity, better oxidation resistance, and superior performance at elevated temperatures compared to tin-plated copper. For aerospace, defense, and high-reliability signal applications where long-term termination stability matters, silver plating is the preferred choice.

What temperature range can silver-plated M16878/13 handle?
With silver-plated copper conductors, M16878/13 is rated for continuous operation from -60°C to +200°C. This is a significant upgrade over tin-plated variants, which are limited to 150°C per NEMA HP-4 specifications.

How does thin-wall insulation benefit aerospace wiring?
Thin-wall construction reduces wire OD and overall harness weight by up to 25% compared to medium-wall wire. In aircraft and satellite applications, this weight savings translates directly to fuel efficiency and increased payload capacity over the system's operational lifetime.

Is this Mil-Spec wire suitable for high-frequency signal transmission?
Yes. FEP has one of the lowest dielectric constants of any commercial insulation material, which minimizes capacitance and signal loss. Combined with silver-plated conductors' low contact resistance, M16878/13 performs well in high-frequency signal and data transmission circuits.

Can I request custom colors or stripe patterns?
Absolutely. We offer standard color options as well as custom stripe combinations to match your wire identification and color-coding requirements. Contact us with your specifications for custom color quotes.

Do you provide compliance documentation?
All M16878/13 wire is manufactured in compliance with RoHS regulations. Full material certifications and test reports are available upon request.

Ready to Source Your M16878/13 Wire?

Need lightweight, high-reliability hook-up wire for avionics, instrumentation, or compact electronic assemblies? The M16878/13 with silver-plated copper conductors delivers thin-wall space savings, superior signal integrity, and 200°C thermal stability. Reach out for pricing, a complete datasheet, or evaluation samples.