Overview

As the defense sector continues to require faster digital networks in avionics, cables need to transmit data reliably at much higher rates. At the same time, the aerospace industry is moving away from proprietary networks to open-source architectures and standardized protocols, like Ethernet.

GORE Ethernet Cables meet the increasing data demands of modern airborne digital networks. We manufacture a selection of cables in several configurations and performance lengths that support standard Ethernet protocols to meet your specific application needs and requirements. You can be confident that our high-density cables will deliver high data rate transmission without failing in demanding aircraft environments for mission success.

Easier Installation with Routable Designs

Our Ethernet cables can significantly reduce size and weight without compromising durability or signal integrity. The smaller cable diameters also allow for greater flexibility and a tighter bend radius. All of this means that our Ethernet cables can be easily installed or retrofitted in new and existing aircraft structures without breaking or failing for less maintenance, downtime and overall costs. You can also reduce additional signal amplification in your system architecture because of the superior electrical performance of our cables, decreasing weight and power requirements even more.

GORE Ethernet Cables provide aircraft system architects and engineers with many benefits that improve electrical and mechanical performance such as:

  • excellent signal integrity with stable performance after installation and over time
  • meet and exceed standardized high-speed data protocol requirements
  • highly robust constructions tolerate harsh aircraft conditions
  • smaller, lighter weight designs with greater flexibility, tighter bend radius
  • less need for additional signal amplification further reduces weight/power requirements
  • compatible with variety of high-speed aerospace connector systems/backshells
  • selected pre-qualified samples with short lead times for prototyping and evaluation
  • low technical risk based on validated product performance in real-world conditions

For more information about the benefits of our cables, please contact a Gore representative.

4 Pairs (Cat5e/6/6a)

Our award-winning Ethernet Cat6a version exceeds stringent electrical requirements and delivers excellent signal integrity with sufficient margin for high-speed data transmission up to 10 Gb at lengths up to 80 m (262 ft). This version is approved to SAE AS6070™ standards that support AS50881 EWIS (electrical wiring interconnection systems) specifications and on the Qualified Products List (QPL). Our Cat6a version is also qualified according to C21091 specifications and has been selected for aircraft program upgrades, like the F-16 and more.

Comparison between GORE Ethernet Cables and standard cables

Reduced cable diameter

Our Ethernet Cat6a cables have a unique compact design that is 24% smaller and 25% lighter than alternative designs. In fact, this 4-pair version is proven to save 5.9 kg/km (13 lb/1000 ft) on aircraft.

Proven Installed Performance

We designed a simulator to evaluate the effects of severe bending on cables while being routed through an airframe. Results showed that our Ethernet Cat6a version delivered lower signal attenuation, reduced crosstalk and improved shielding effectiveness after routing compared to alternative cables available on the market today.

CONNECTOR-CABLE COMPATIBILITY

Download our best practices for terminating our 4-pair Ethernet cables with leading high-speed aerospace connectors and related electrical data for connector-cable compatibility.

Aerospace Ethernet - 4 Pairs - Cable Construction
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Engineered fluoropolymer jacket

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Braided shield

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Aluminized polyimide shield

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Silver-plated copper / SPC alloy conductor

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FEP filler

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Color-coded composite dielectric

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High-density construction of GORE Ethernet Cables (4 Pairs, Cat5e/6/6a)

Applications

GORE Ethernet Cables (4 Pairs, Cat5e/6/6a) are engineered to perform reliably in a variety of aircraft applications, including:

  • avionics network
  • cabin/flight management systems
  • digital video systems
  • Ethernet backbone
  • program upgrades (C-130, F-16, KC-135, UH-60)

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Properties

These values demonstrate the electrical, mechanical and environmental performance of GORE Ethernet Cables (4 Pairs, Cat5e/6/6a).

Download the data sheet for technical information and performance data.

Electrical Property Value
Standard Impedance (Ohms) 100 ± 10
Typical Operating Voltage (V) < 15
Nominal Velocity of Propagation (%) 80
Nominal Time Delay ns/m (ns/ft) 4.10 (1.25)
Capacitance pF/m (pF/ft) 42.6 (13.0)
Minimum Near-End Crosstalk (NEXT) (dB)
 10 MHz
 100 MHz
 500 MHz
 
59.2
52.3
42.2
Shielding Effectiveness (dB) > 55
Dielectric Withstanding Voltage (Vrms)
  Conductor-to-Conductor
  Conductor-to-Shield
 
1500
1000
Mechanical / Environmental Properties Value
Jacket Material Engineered Fluoropolymer
Jacket Color White (Laser Markable)
Conductor Silver-Plated Copper or SPC Alloy
Conductor Color-Coding Solid Blue & White / Blue Stripe
Solid Orange & White / Orange Stripe
Solid Green & White / Green Stripe
Solid Brown & White / Brown Stripe
Dielectric Material ePTFE/PTFE
Temperature Range (°C) -65 to +200
Part Numbers & Drawings

Download the drawings to view cable characteristics, like diameter, weight, minimum bend radius and insertion loss.

Cat6a Part Number AWG Size
(Stranding)
RCN8966-24 24 (19/36)
RCN9034-24 24 (19/36)
RCN8966-26 26 (19/38)
RCN9047-26 26 (19/38)
RCN9034-28 28 (19/40)
Cat5e Part Number AWG Size
(Stranding)
GSC-01-83471-00 24 (19/36)
GSC-01-83472-00 26 (19/38)
Qualifications

GORE Ethernet Cables (4 Pairs, Cat5e/6/6a) have undergone substantial qualification testing to ensure they meet the most current industry standards and our customers’ requirements.

Fill out a short form to receive a complimentary sample of our pre-qualified cables for prototyping and evaluation from our authorized global distributors, Air Cost Control (Europe) or WireMasters (US).

Download Gore’s best practices for terminating GORE Ethernet Cables (4 Pairs, Cat5e/6/6a) with leading high-speed aerospace connectors and related electrical data for cable-connector compatibility.

Download an assembly drawing for connector part numbers.

Note: Drawing is for reference only to provide customers with relevant information related to connector options included in Gore’s best practices for terminating cable assemblies. Gore does not build assemblies specified in the drawing.

Quadrax (Cat5e)

When you don’t want to use a standard 4-pair design in your system architecture, our star quadrax design is a perfect alternative to meet Ethernet Cat5e protocol requirements. These dual differential pairs transmit continuous bi-directional, high-speed signals up to 100 MHz at lengths up to 70 m (230 ft) using size 24 AWG and 50 m (164 ft) using size 26 AWG. They’re also proven to be a reliable substitute to dual twisted pair cables for meeting high data rate needs.

We're the original inventor of this pioneering quadrax cable geometry that is about 40% smaller than dual twisted pair constructions. Our cable’s lightweight build is also proven to save more than 5.0 kg (11 lb) on aircraft like the latest fifth-generation F-35.

Construction of GORE Ethernet Quadrax, Cat5e cables)
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Engineered fluoropolymer jacket

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ePTFE binder

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ePTFE binder

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Silver-plated copper alloy conductor

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FEP filler

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Color-coded composite dielectric

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Braided shield

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Lightweight build of GORE Ethernet Cables (Quadrax, Cat5e)

Applications

GORE Ethernet Cables (Quadrax, Cat5e) are engineered to perform reliably in a variety of aircraft applications, including:

  • avionics networks
  • box-to-box systems
  • digital visual interface (DVI)
  • Ethernet backbone
  • flight control
  • mission systems
  • propulsion control

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Properties

These values demonstrate the electrical, mechanical and environmental performance of GORE Ethernet Cables (Quadrax, Cat5e).

Download the data sheet for technical information and performance data.

Electrical Property Value
Standard Impedance (Ohms) 100 ± 10
Typical Operating Voltage (V) < 15
Nominal Velocity of Propagation (%) 80
Nominal Time Delay ns/m (ns/ft) 4.10 (1.25)
Capacitance pF/m (pF/ft) 50.0 (15.2)
Minimum Near-End Crosstalk (NEXT) (dB)
 10 MHz
 100 MHz
 
50.0
35.0
Dielectric Withstanding Voltage (Vrms)
  Conductor-to-Conductor
  Conductor-to-Shield
2500
Mechanical / Environmental Properties Value
Jacket Material Engineered Fluoropolymer
Jacket Color White (Laser Markable)
Conductor Silver-Plated Copper Alloy
Conductor Color-Coding Blue/Red, Green/Yellow
Dielectric Material ePTFE/PTFE
Temperature Range (°C) -65 to +200
Part Numbers & Drawings

Download the drawings to view cable characteristics like diameter, weight, minimum bend radius and insertion loss.

Part Number AWG Size
(Stranding)
GSC-03-84608-00 24 (19/36)
GSC-03-84820-00 26 (19/38)
Qualifications

GORE Ethernet Cables (Quadrax, Cat5e) have undergone substantial qualification testing to ensure they meet the most current industry standards and our customers’ requirements.

  • ABD0031 (AITM 2.0005); BSS7230; FAR Part 25, Appendix F, Part I: Flammability
  • ABD0031 (AITM 3.0005); BSS7239: Toxicity
  • ABD0031 (AITM 3.0008B); BSS7238; FAR Part 25, Appendix F, Part V: Smoke Density
  • AFDX/ARINC 664, Part 7: Ethernet Networks
  • ANSI/NEMA WC 27500: Environmental Testing, Jacket and Marking
  • IEEE 802.3: Ethernet 100BASE-T / 1000BASE-T (2 cables)
  • SAE AS4373™: Test Methods for Insulated Electric Wire (Contact Gore for available data)

Fill out a short form to receive a complimentary sample of our pre-qualified cables for prototyping and evaluation from our authorized distributors, Air Cost Control (Europe) or WireMasters (US).

2 Pairs (Cat5e)

For Ethernet Cat5e protocol, our 2-pair cable is an ideal solution if you don’t want to use a 4-pair or quadrax design in your system architecture. This version preserves signal integrity, significantly exceeds crosstalk requirements, and reliably carries high-speed data up to 1 GHz. You can also position 2 of our cables side by side to achieve Ethernet 1000BASE-T performance.

Our 2-pair Ethernet cable is mechanically strong and can easily tolerate rough aircraft conditions, like extreme temperatures and constant vibration during flight. It has a smaller, more flexible form factor with tighter bending capability. If you’re an aircraft maintainer, then you’ll find it much easier and faster to route our cable, especially in complex airframes with less space.

Construction of GORE Ethernet Quadrax Cat5e - US
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Engineered fluoropolymer jacket

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Braided shield

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Aluminized polyimide shield

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Silver-plated copper / SPC alloy conductor

닫기

Color-coded composite dielectric

닫기

Smaller form factor of GORE Ethernet Cables (2 Pairs, Cat5e)

Applications

GORE Ethernet Cables (2 Pairs, Cat5e) are engineered to perform reliably in a variety of aircraft applications, including:

  • avionics networks
  • cabin management systems
  • digital video systems
  • Ethernet backbone
  • serial buses

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

Properties

These values demonstrate the electrical, mechanical and environmental performance of GORE Ethernet Cables (2 Pairs, Cat5e).

Download the data sheet for technical information and performance data.

Electrical Property Value
Standard Impedance (Ohms) 100 ± 10/-5
Typical Operating Voltage (V) < 15
Nominal Velocity of Propagation (%) 80
Nominal Time Delay ns/m (ns/ft) 4.10 (1.25)
Capacitance pF/m (pF/ft) 41.0 (12.5)
Minimum Near-End Crosstalk (NEXT) (dB)
 10 MHz
 100 MHz
 
59.2
52.3
Dielectric Withstanding Voltage (Vrms)
  Conductor-to-Conductor
  Conductor-to-Shield
 
1500
1000
Mechanical / Environmental Property Value
Jacket Material Engineered Fluoropolymer
Jacket Color White (Laser Markable)
Conductor Silver-Plated Copper or SPC Alloy
Conductor Color-Coding Solid Green & Green/White Stripe
Solid Orange & Orange/White Stripe
Dielectric Material ePTFE/PTFE
Temperature Range (°C) -65 to +200
Part Number & Drawing

Download the drawing to view cable characteristics like diameter, weight, minimum bend radius and insertion loss.

Part Number AWG Size
(Stranding)
RCN9133-26 26 (19/38)
Qualifications

GORE Ethernet Cables (2 Pairs, Cat5e) have undergone substantial qualification testing to ensure they meet the most current industry standards and our customers’ requirements.

  • ABD0031 (AITM 2.0005); BSS7230; FAR Part 25, Appendix F, Part I: Flammability
  • ABD0031 (AITM 3.0005); BSS7239: Toxicity
  • ABD0031 (AITM 3.0008B); BSS7238; FAR Part 25, Appendix F, Part V: Smoke Density
  • ANSI/NEMA WC 27500: Environmental Testing, Jacket and Marking
  • ANSI/TIA 568-C.2: Performance Requirements
  • IEEE 802.3: Ethernet 100BASE-T /1000BASE-T (2 cables)
  • SAE AS4373™: Test Methods for Insulated Electric Wire (Contact Gore for available data)

Fill out a short form to receive a complimentary sample of our pre-qualified cables for prototyping and evaluation from our authorized distributors, Air Cost Control (Europe) or WireMasters (US).

Cable Routing Simulators

Gore has been a long-time supporter of testing our products extensively to show how reliably they perform in real-world conditions before launching them to market. So, we designed a cable routing simulator to evaluate the effects of severe bending on high-speed data cables while being routed through an airframe.

Testing characteristics such as return loss and crosstalk after routing through the simulator verifies whether a cable can withstand complex installation challenges that can degrade signal integrity and lead to failures over time. Now, manufacturers can be sure they’re getting a robust Ethernet cable that delivers superior performance over the life of the aircraft — ultimately reducing maintenance, downtime, and total costs.

For more information about our cable routing simulator and the effects of installation on Ethernet Interconnects, download the white paper.

We also designed an aviation display that mimics an airframe bulkhead to demonstrate the challenges engineers face when designing an Ethernet system. We connected our cables to common avionic components, like cockpit displays, mission computers and aircraft survivability equipment. Our Ethernet cables were also terminated with leading aerospace connector systems that support standard protocols.

Our demonstration shows how easy it is to bend, flex and route our cables through existing bulkheads with tight spaces.

Watch Gore engineers in these videos and more on YouTube demonstrating the durability of GORE Aerospace High Speed Data Cables.

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