Overview

RELIABLE HIGH-SPEED DATA TRANSFER

As the defense sector requires faster digital networks in avionics, cables must transmit data reliably at much higher rates. The aerospace industry is also moving away from proprietary networks to open-source architectures and standardized protocols, like Ethernet.

GORE Ethernet Cables are designed with speed, signal integrity and durability in mind. We offer several high-density configurations and performance lengths that support Cat5e, Cat6 and Cat6a protocols to meet your specific application needs and requirements. Available in 4 pairs, quadrax or 2 pairs, these cables provide the fast speeds, excellent signal integrity and robustness needed to support today’s airborne digital networks and critical avionics.

COMPACT, ROUTABLE DESIGNS

Our Ethernet cables’ compact designs offer significant size and weight reduction over competing cables. Their slender diameters are inherently lighter with more flexibility without compromising durability, signal integrity or transmission speed. They can be easily installed, retrofitted and maintained, even when space is at a premium. Maintainers will appreciate how quickly it is to install our cables, saving valuable time and replacement costs.

Whatever configuration you pick for your defense aircraft, you can be confident that GORE Ethernet Cables will perform at fast speeds without failure after routing and throughout missions.

Features & Benefits

GORE Ethernet Cables are engineered with unique features that make them more durable against challenging environmental factors and aircraft conditions, including:

  • chemically inert, temperature- and abrasion-resistant, EMI shielding materials
  • slender, lightweight, highly flexible cable diameters
  • several configurations and performance lengths

Our cables provide aircraft system architects and engineers with many benefits that improve electrical, mechanical and environmental performance, like:

  • meet Cat 5e, Cat 6 and exceed Cat 6a high speed data protocol requirements
  • proven excellent signal integrity with stability after installation and over time
  • low crosstalk performance for less RF signal interference among electronic systems
  • high-density constructions tolerate harsh aviation conditions
  • valuable weight savings with smaller, lighter weight designs
  • quick, easy routing in tight areas from greater flexibility and small bending
  • compatible with a variety of high-speed connector systems and backshells
  • selected pre-qualified samples with short lead times for prototyping and evaluation
  • low risk based on validated product performance in real-world conditions

For more information about the features and benefits of our cables, contact a Gore representative today.

4 Pairs (Cat5e/6/6a)

IMPROVED SIGNAL PERFORMANCE

Our award-winning Ethernet Cat6a version exceeds stringent protocol requirements, maintaining clear data transmission at speeds 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.

Our Ethernet Cat6a cables improve signal integrity and provide additional margin that helps overcome routing issues and mission challenges. They’re proven to outperform several leading alternative cables with:

  • vastly better insertion loss to crosstalk ratio for more reliable data transmission
  • lower crosstalk and consistent impedance control at higher frequencies after routing
  • sufficient margin below the specification limit for return loss after routing
  • reduced RF interference at higher frequencies for better noise immunity and less EMI missions among electronics
PROVEN INSTALLED PERFORMANCE
Gore’s Reduced Ethernet Cat6a Cable Diameter

Reduced cable diameter

Based on test results using cable routing simulators that we built, our high-density Cat6a version with a multi-layer construction delivers proven installed performance compared to leading alternatives.

Not only that, but our 4-pair design is 24% smaller and 25% lighter than standard designs. In fact, they’re proven to save 5.9 kg/km (13 lb per 1000 ft) in military aircraft.

PROVEN PERFORMANCE ACROSS AIRCRAFT APPLICATIONS

GORE Ethernet Cables (4 Pairs, Cat5e/6/6a) deliver valued performance after installation and over time in a variety of applications, like:

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

Our 4-pair version can also be terminated with a variety of leading high-speed aerospace connector systems, allowing designers to choose the best option for every application.

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

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

Download the data sheet for technical information and performance data.

Electrical Property Value
Transmission Speed Gb/s Up to 10
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
 at 10 MHz
 at 100 MHz
 at 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 Expanded PTFE/PTFE
Temperature Range °C -65 to +200
Part Numbers & Drawings

We invite you to download our drawings to view cable characteristics, like diameter sizes, weight and insertion loss values.

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)

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

Fill out a short form to get samples of our prequalified cables in 48 hours for prototyping and evaluation. For more information about the qualifications of our cables and complimentary samples, contact a Gore representative today.

Construction of Gore’s Ethernet 4-Pair Cables
A
B
C
D
E
F

Engineered fluoropolymer jacket

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Braided shield

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Aluminized polyimide shield

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FEP filler

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Silver-plated copper / SPC alloy conductor

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Color-coded composite dielectric

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

Quadrax (Cat5e)

ORIGINAL INNOVATIVE DESIGN

When you don’t want to use a standard 4-pair design in your aircraft system architecture, our star quadrax design is a perfect alternative to meet Ethernet Cat5e protocol requirements.

These dual differential pairs transmit continuous bi-directional signals at high speeds in a variety of applications, like flight and propulsion control, box-to-box systems and more. Their performance is proven reliable 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.

This pioneering cable geometry, which we invented originally, is lightweight and roughly 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.

Yet, our cables offer robustness throughout every mission and over the system's lifetime. Our star quadrax Ethernet Cat5e version is a proven reliable substitute to dual twisted pair constructions for meeting high data rate needs.

PROVEN PERFORMANCE ACROSS AIRCRAFT APPLICATIONS

GORE Ethernet Cables (Quadrax, Cat5e) are reliable substitutes to dual twisted pair constructions for meeting high data rate needs in a variety of applications, like:

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

Our quadrax version can also be terminated with a variety of leading high-speed aerospace connector systems and backshells, like ARINC and MIL-STD-38999 with size 8 contacts. If you have any questions or to discuss your specific application needs, contact a Gore representative today.

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

Download the data sheet for technical information and performance data.

Electrical Property Value
Transmission Speed MHz Up to 100
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) 45.0 (13.7)
Minimum Near-End Crosstalk (NEXT) dB
 at 10 MHz
 at 100 MHz
 
50.0
35.0
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 Alloy
Conductor Color-Coding Blue/Red, Green/Yellow
Dielectric Material Expanded PTFE/PTFE
Temperature Range °C -65 to +200
Part Numbers & Drawings

We invite you to download our drawings to view cable characteristics, like diameter sizes, weight, minimum bend radii and insertion/return loss values.

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

GORE Ethernet Cables (Quadrax, Cat5e) for Defense Aircraft 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 get samples of our prequalified cables in 48 hours for prototyping and evaluation. For more information about the qualifications of our cables and complimentary samples, contact a Gore representative today.

Construction of Gore’s Ethernet Quadrax Cables
A
B
C
D
E
F

Engineered fluoropolymer jacket

Close

ePTFE binder

Close

Silver-plated copper alloy conductor

Close

FEP filler

Close

Color-coded composite dielectric

Close

Braided shield

Close

Lightweight, robust build of GORE Ethernet Cables (Quadrax, Cat5e)

2 Pairs (Cat5e)

EXCEED CROSSTALK REQUIREMENTS

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 small, robust version preserves signal integrity, significantly exceeds crosstalk requirements and reliably carries up to 1 GHz of high-speed data.

For Ethernet 1000BASE-T performance, positioning our cables side by side gives engineers more flexibility when designing avionics systems.

Applications

GORE Ethernet Cables (2 Pairs, Cat5e) are reliable substitutes to dual twisted pair constructions for meeting high data rate needs in applications, like:

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

Our 2-pair version can also be terminated with a variety of leading high-speed aerospace connector systems and backshells, like ARINC and MIL-STD-38999 with size 8 contacts. If you have any questions or to discuss your specific application needs, contact a Gore representative today.

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

Download the data sheet for technical information and performance data.

Electrical Property Value
Transmission Speed GHz Up to 1
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
 at 10 MHz
 at 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/SPC Alloy
Conductor Color-Coding Solid Green & Green/White Stripe
Solid Orange & Orange/White Stripe
Dielectric Material Expanded PTFE/PTFE
Temperature Range °C -65 to +200
Part Number & Drawing

We invite you to download our drawing to view cable characteristics, like diameter size, weight and insertion loss values.

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

GORE Ethernet Cables (2 Pairs, Cat5e) for Defense Aircraft 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 get samples of our prequalified cables in 48 hours for prototyping and evaluation. For more information about the qualifications of our cables and complimentary samples, contact a Gore representative today.

Construction of Gore’s Ethernet 2-Pair Cables
A
B
C
D
E

Engineered fluoropolymer jacket

Close

Braided shield

Close

Aluminized polyimide shield

Close

Silver-plated copper / SPC alloy conductor

Close

Color-coded composite dielectric

Close

Smaller Form Factor of GORE Ethernet Cables (2 Pairs, Cat5e)

Cable Routing Simulators

TESTING IN REAL-WORLD CONDITIONS

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.

PROVEN INSTALLED PERFORMANCE

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.

GREATER FLEXIBILITY

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.

More Information

LEARN MORE ABOUT GORE ETHERNET CABLES OR ORDER NOW

Available in several designs to meet Cat5e, Cat6 and Cat6a protocols, GORE Ethernet Cables are the proven solutions for airborne digital networks. For more information or to discuss your specific military aircraft application needs, contact a Gore representative

If you're ready to order our cables in 4 pairs, quadrax or 2 pairs, contact one of our defense wire and cable distributors. You can also request tested, prequalified samples, which are complimentary and available within 48 hours.

Resources

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Event

Join Us at the Aviation Forum

December 7, 2021 - December 8, 2021

Visit our Booth F16 to tell us about your latest airframe and aviation system developments and hear more about our solutions for the civil aerospace industry. We’re looking forward to meeting and talking in person again after so long!

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Visit Us at Cribbins

November 15, 2021 - November 17, 2021

We’re excited to be able to meet and talk in person again after so many virtual meetings! Stop by Booth 609 to talk with us about your latest aviation and airframe system developments. And you don’t want to miss our latest Fiber Optic Cables Demonstration, so come by and ask to see it.

W. L. Gore & Associates High Performance Aerospace Wires Set Gold Standard With Industry Award

Posted November 8, 2021

W. L. Gore & Associates (Gore) announced today that its GORE® High Performance Aerospace Wires, GWN3000 Series, were recognized among the 2021 Military & Aerospace Electronics Technology Innovators Awards. An independent panel of esteemed judges from the aerospace and defense community recognized Gore as a gold honoree for the second consecutive year. The company’s PHASEFLEX® Microwave/RF Test Assemblies were recognized in 2020.

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Gore Exhibiting at 2021 Global Defense Helicopter

November 2, 2021 - November 4, 2021

Visit our booth during Europe’s largest military helicopter event to see our extensive portfolio of proven solutions that the military has relied on and trusted for decades. On Thursday, November 4th, don’t miss the presentation from our experts about Gore’s aerospace interconnection solutions and materials for existing and next-gen rotorcraft.

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