Busbar and wire stripping in the avionics industry is an error-prone stage in production, given the specialized nature of aerospace wiring and the extreme reliability required for flight safety. The main issues stem from the use of extremely thin, tough insulation or coating and the severe consequences of even minor conductor damage. MIL-Spec wire insulation that is lightweight and heat-resistant can be made of Teflon (PTFE), Tefzel (ETFE), or Kapton (polyimide) – with walls as thin as 0.15 mm, these materials are difficult to strip with standard methods without damaging the underlying shield or conductor.
Wire Stripping by Laser
Laser ablation of wire and busbar insulation is a contactless removal process that can uncover the metal core without nicks, broken strands, charring, or stretching. CMS Laser provides laser processing solutions for multiple-gauge wires in the range of 12 to 24 AWG, of round or flat type. Our wire stripping machines integrate dual CO2 lasers operating at 10.6 µm, 9.4 µm, or other wavelengths, selected according to the polymer’s absorption properties and the required beam penetration depth. In such configuration, the insulation is ablated cleanly and uniformly around the circumference of the wire, while the metal core reflects laser radiation rather than absorbing it, thereby avoiding thermal loading.
Focus on Avionics
In the development of laser systems for avionics wire processing, Team CMS Laser carefully considers the extreme tolerances and safety requirements of the aerospace industry. Our engineers, experienced with every laser source available on the market today, evaluate how your materials interact with different laser wavelengths and select one specifically matched to the insulation or coating composite used in your production. By tailoring wavelength, pulse characteristics, and energy delivery to the material, we ensure the process maintains zero-defect conductor integrity, adhering to rigorous industry standards such as NASA-STD-8739.4, FAA/EASA regulations, and military specifications such as SAE-AS22759. Our systems are engineered for quality, performance, and safety, in alignment with laser wire stripping best practices outlined in SAE-AIR6894A.
CMS Laser Advantages
We build comprehensive solutions that are semi- or fully automated, featuring on-the-fly processing, mechanized spool handling and wire collection, multi-station processing, machine vision for quality assurance, and other custom configurations. Laser wire marking and automated wire blade cutting to length are additional functionalities we integrate into our wire processing systems by your request. You can learn more about high-precision UV laser marking of wires in the aerospace industry in this blog.
Since 1983, CMS Laser helps manufacturers improve consistency, reduce manual effort, and increase throughput with custom laser systems and proprietary software controls.
Here’s what we can do for your wire and busbar processing operations in aerospace:
- Multi-functionality – to perform stripping, marking, and cutting
- Ultra-fine insulation removal – to handle the miniaturization of modern avionics
- Variable gauge and strip lengths – to meet varying requirements
- On-the-fly processing – non-stop processing while the wire is in motion
- Advanced software – to program and store recipes, connect to database
- Real-time quality assurance – machine vision for in-line inspection
- Industrial durability – to support high-volume, continuous operation
- Built-in safety features – laser-safe windows, interlocks, fume extraction
All systems are designed with a focus on operator safety, usability, and consistent performance. Our machines comply with CDRH Class I laser safety requirements, incorporating fully enclosed, interlocked workcells that ensure safe operation without the need for additional protective measures.
Contact our product specialists today to learn how laser wire processing can improve your processes.
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