Overview

Maintaining signal integrity under difficult aerospace environments is essential to the reliability of mission-critical systems in aircraft. Starting with continuous flexing during routing through flight conditions, like repeated shock/vibration during flight, extreme altitude/temperature changes, and harsh contaminants. At the same time, airframe assemblies must be both lightweight and durable to improve fuel efficiency and reduce operating costs.

In fact, we conducted independent studies and research showing that globally more than 75% of microwave/RF assemblies are frequently replaced due to damage during installation or operation. So, costs can quickly add up with replacing assemblies, extra labor, and more maintenance and downtime!

LIGHTWEIGHT SOLUTION WITH THE LOWEST INSERTION LOSS

Award-wining GORE-FLIGHT Microwave Assemblies are proven to deliver the lowest insertion loss and more reliable VSWR after installation compared to leading competitor assemblies. Our rugged yet flexible airframe assemblies can easily withstand rigorous routing, maintenance activities, and flight conditions for lifetime performance. They’re also lighter weight compared to leading competitor designs, which improves fuel efficiency and increases payload.

Our assemblies have been thoroughly tested and qualified to meet stringent defense specifications and requirements for current and future generation fixed-wing and rotary-wing aircraft. With this high level of performance, our assemblies reduce costly production delays, field service frequency, and the need for purchasing replacement assemblies.

Aircraft manufacturers no longer have to accept the practice of replacing microwave/RF assemblies because they get damaged during installation. A fit-and-forget philosophy is now a reality because GORE-FLIGHT Microwave Assemblies provide the most cost-effective, lightweight solution that ensures mission-critical system performance for pilots.

Image of cable construction of GORE-FLIGHT Microwave Assemblies, Types 65 and 6E
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Abrasion-resistant braided jacket

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Liquid barrier

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Crush member

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Vapor barrier

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Torque-resistant braid

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Helically wrapped, silver-plated outer conductor

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Silver-plated conductor

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ePTFE dielectric

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Rugged construction of GORE-FLIGHT Microwave Assemblies, Types 65 and 6E.

Applications

GORE-FLIGHT Microwave Assemblies are engineered to perform reliably in a variety of aircraft applications, including:

Innovators Awards

GORE-FLIGHT Microwave Assemblies earned a platinum award for product innovation from Military & Aerospace Electronics.

Find out more

  • C5ISR
  • airborne electronic surveillance / countermeasures / jamming
  • EW (Electronic Warfare) systems
  • RWR (Radar Warning Receiver) systems
  • radar interconnects
  • electronic / signal intelligence
  • navigation / communication systems

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

Benefits

GORE-FLIGHT Microwave Assemblies provide aircraft system architects and engineers with many benefits that improve electrical and mechanical performance such as:

  • outstanding signal integrity with lowest insertion loss before/after installation
  • lower installation costs due to fewer failures and reduced aircraft production delays
  • improved fuel efficiency and increased payload with lightweight assembly
  • longer system life and reduced downtime due to mechanically robust construction
  • less RF interference among electronic systems due to superior shielding effectiveness
  • proven compliance with stringent industry requirements

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

Properties

These values demonstrate the electrical, mechanical and environmental performance of GORE-FLIGHT Microwave Assemblies.

Download the data sheet for more technical information — including qualifications, performance data, torque values, connector options, and ordering information.

Electrical Property Value
Type 04 Type 65 Type 6E
Maximum Frequency (GHz) 18 18 18
Typical VSWR through 18 GHz (straight connector) 1.25:1 1.25:1 1.25:1
Guaranteed VSWR through 18 GHz (straight connector) 1.40:1 1.40:1 1.40:1
Typical Insertion Loss at 18 GHz (dB/ft) 0.633 0.342 0.198
Guaranteed Insertion Loss at 18 GHz (dB/ft) 0.673 0.384 0.208
Standard Impedance (Ohms) 50 ± 1 50 ± 1 50 ± 1
Nominal Dielectric Constant 1.4 1.35 1.35
Nominal Velocity of Propagation (%) 85 86 86
Nominal Time Delay ns/in (ns/cm) 0.103 (0.04) 0.0984 (0.0387) 0.0984 (0.0387)
Shielding Effectiveness through 18 GHz (dB) > 90 > 90 > 90
Mechanical / Environmental Property Value
Type 04 Type 65 Type 6E
Overall Diameter in (mm) 0.18 (4.55) 0.24 (6.1) 0.35 (8.9)
Nominal Weight lb/ft (g/m) 0.027 (41) 0.040 (60) 0.084 (125)
Minimum Bend Radius in (mm) 0.5 (12.5) 1.0 (25.4) 1.9 (48.3)
Temperature Rangea (°C) -55 to +125 -55 to +125 -55 to +125
Concentrated Load per MIL-T-81490 paragraph 4.7.18 (lb) > 150 > 150 > 150

a For applications outside of these temperatures, please contact a Gore representative.

Installation Simulator

Gore has long been a proponent of showing accurately how its products and technologies function in real-world environments before bringing them to market. Because nearly one-third of cable failures occur during installation, this is a crucial risk factor that shouldn't be minimized. Damaged airframe assemblies can lead to compromised signal integrity and failures over time, additional testing, and maintenance and replacement costs.

Jim Foreman
Jim Foreman, Product Manager

With our installation simulator, aircraft manufacturers can be confident they are getting a reliable microwave/RF assembly solution that withstands the rigors of installation and reduces the total cost of ownership.

"Aircraft manufacturers need reliable solutions that can be installed deep within an aircraft and left there for the life of the platform. Therefore, we want to create 'fit-and-forget' solutions that will survive the demanding environments within an aircraft," said Jim Foreman, Product Manager at Gore.

"We're committed to designing next-generation products that solve key challenges and mitigate risk for aircraft," said Paul Pino, Lead Principal Design Engineer at Gore. "To do this, we test and simulate real-world conditions to ensure that our products do what we say they will do, consistently and reliably even in harsh conditions."

For more information about our Installation Simulator, download the white paper, 
Proving Installed Performance of Airframe Microwave Assemblies.

Also, download the white paper, Reducing Life Cycle Costs with Reliable Airframe Microwave Assemblies.

Videos

Watch these videos and more on YouTube of Gore engineers demonstrating the benefits of GORE® Microwave/RF Assemblies.

Online Tools

Easy to Use, Fast Results

Gore’s online resources are designed specifically to make it easy for you to select the right microwave/RF assembly for your specific application requirements.

GORE Online Cable Builder Tool

NEW Microwave/RF Cable Assembly Builder allows you to design an assembly with ease from your desktop, tablet or mobile phone. Whether you’re working in aerospace and defense, spaceflight or test and measurement environments, you can design an assembly to meet your specific needs. Once you design your assembly, you can quickly download custom data sheets for your builds. You can also submit your builds for a quote, and our specialists will review your designs and application requirements.

Microwave/RF Cable Assembly Calculator allows you to calculate insertion loss, VSWR and other parameters of Gore’s assemblies for different cable types. Select and compare up to three assemblies at a time.

If you have questions about our assemblies and want to discuss your specific application needs, please contact a Gore representative.

Resources

Recent News

Event

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.

Press Release

W. L. Gore & Associates Data Cables Earn German VG Military Qualification

Posted September 14, 2021

Gore announced today several of its next-generation data cable products for aerospace and defense applications have earned an important qualification. The prestigious VG designation from the Bundeswehr, Germany’s unified armed forces as well as related civilian administrative and procurement organizations, is expected to facilitate further adoption of these cables for military use.

Press Release

W. L. Gore & Associates Offers Ultra-low-loss 12G-SDI Coaxial Video Cable for Defense Applications

Posted September 10, 2021

Gore announced the expansion of its Coaxial Cables line for defense land system applications. The new product is smaller and lighter than previous offerings, yet capable of transmitting ultra-high-definition (UHD) 4K video with excellent shielding from radio frequency interference.

Event

W. L. Gore & Associates Exhibiting Virtually at IMS2021

June 20, 2021 - June 25, 2021

Gore is exhibiting virtually at this year’s International Microwave Symposium (IMS), and you’re invited to visit our virtual booth. We’ll describe how our proven portfolio of durable microwave/RF test assemblies delivers stable and consistent performance for reliable 5G test results.

View all News & Events

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