Excellence solutions in
signal and electric power transmission for
the aerospace industry.

Solutions to recurring problems

Protezione_Conduit_PrestelMECHANICAL STRESS: protection from damages due to vibrations is a main issue for aircrafts manufacturers. Bundles are protected from friction using several kinds of braids, sleeves and conduits.

Protezione_Nomex_Prestel_con_CartellinoNOMEX BRAID: Strong mechanical protection; low flammability and resistance to most chemicals; excellent abrasion and cut-through resistance; oil and water repellent; highly flexible. Temperature range from -60°C to 260°C.

CONDUITS:  recommended for crush protection, abrasion protection, and high pull or tensile strength. Metal-core conduit provides optimal EMI/RFI shielding. Heat-resistant conduit materials, such as PFA, suitable for temperatures from -70°C to 260°C.

MIL-DTL-23053 SLEEVES: superior abrasion and solvent resistance; excellent physical, chemical and electrical properties; conforms to irregular shapes; flame retardant. Temperature range from -75°C to 175°C.

The highly demanding working conditions might generate pernicious traction phenomena on wires. Crimping is for this reason considered a special process and its reliability  is checked through a specific traction test. The minimum imposed value for the testing sample depends on the wire section and on the type of terminal/contact. Our dynamometer can measure up to 4700 N ±0,34%.


TEMPERATURE: up today Prestel Avio has been required by its Customers to manufacture harnesses with components suitable for the following conditions:

FIREJACKET THERMOTUBIX AS1072: silicone coated fiberglass sleeve with a high level of heat dissipation. Range of temperature: from -54°C to 260°C, for a short time can resist to open flame up to 1093°C.i.e.: Specifically used in engine harnesses sets.

HT CONNECTORS: designed for high temperature, fire-retardant conditions, moisture, atmospheric changes, fuels, cleaning agents, coolants and hydraulic fluids in aerospace engines. High temperature connectors meet several European, General Electric and Rolls Royce specifications. Materials provide operation up to 200°C and Firewall capability to 260°C. i.e.: Prestel manufactures harnesses for wings and back fuselage of EFA requiring these components.

MIL-W-25038 & PAN6411 WIRES: designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure. This heavy-duty, non-asbestos construction offers excellent mechanical performance and abrasion resistance. Temperature range from -65°C to 260°C.

Sigillatura_Manicotto_PrestelSEALING: swamp areas are another typical critical issue. Prestel has been approaching this kind of problem with its Customers through a specific process performed using the most effective components.

SEALING PASTES: providing an environmental sealing. I.E.:

  •  Tyco Raychem S1125: epoxy/polyamide 2-part paste, non-conductive for mechanical protection and fluid resistance. Temperature range: -55°C to 135°C
  •  Tyco Raychem S1184: epoxy 2-part adhesive designed to make terminations withstanding high temperatures and aggressive solvents and fuels. Temperature range: -55°C to 150°C.


MIL-DTL-23053/13 SLEEVE (VITON) : fluoroelastomer sleeve designed for high temperature, high resistance to impact and abrasion and to fuels, lubricants, acids and solvents. Temperature range: from -40°C to 200°C.

MOLDED PARTS: provide rugged mechanical and environmental protection, fluid and heat resistance. Range temperature: from -75°C to 200°C (depending on the chosen product).

SHIELDS:for many applications, shields are the most important element in controlling EMI (electromagnetic interference )/RFI (radio frequency interference). Prestel therefore operates both on wires’ shield and on shielding bundles.

Schermatura_360_PrestelWIRES’ SHIELD PROCESSING:

  •  connecting all cables’ shields using specific solder sleeves.
  •  connecting all cables’ shields using knitted wire mesh.

Schermatura_9999_PrestelBUNDLES SHIELDING: covering where necessary harnesses using Metal, Composite, Fabric and Microfilament Tubular Braids. When necessary such braid is covered by an additional outer protection (i.e. Nomex braid).