Problem:  Approached by a leading company in the aerospace design and engineering industry, Bay Associates was challenged with the manufacturing of a series of Teflon®-insulated, two-conductor communications cables that would serve as a part of the total communication link for the International Space Station. The unique design specifications required a 70 ohm impedance with tight tolerance levels and other demanding electrical, size, and weight requirements. Because of the unique materials and stringent electricals required for the application, the contractor needed a cable specialist capable of manufacturing the challenging specification, the willingness to run minimum footage, and the ability to work under the demanding MIL Spec and space environment requirements.

Solution:  Specializing in custom cable design and manufacturing with small minimum production runs and quick turnarounds, the contractor's requirements were the perfect challenge for Bay Associates. Using unique processing capabilities developed by Bay's in-house research & development and engineering departments, Bay Associates was able to layer the complex series of varying densities of Teflon® around each conductor as specified and meet the tight electrical tolerances.

Problem:  When an aerospace manufacturer suddenly lost its source of supply for an aviation spark plug wire that had challenging design requirements, they needed to find a new source that could handle the unique design and the large continuous production runs needed. The specification called for the jacket and final shield of the cable to be pushed back from the other components of the cable, allowing for termination and then to spring back to original form over the termination end. Making the search for a new source especially difficult, the cable design required a manufacturer capable of braiding fiberglass in addition to the tricky "push back" requirements for the metal braid and jacket.

Solution:  Presented with the challenge, Bay Associates' team of engineers devised a unique process that would prevent the inner insulation from heating and melting during the final manufacturing processes, keeping the metal shield from embedding itself in the insulation. With the shield prevented from unwanted embedding, the shield and jacket allowed for the "push back" needed. Bay's wide range of manufacturing capabilities allows for the braiding of an array of materials from precious metals and exotic alloys to fiberglass and synthetic fibers.

For more information about our products or to find out how we can help you with your specific application, please contact us.

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