MIL-W-16878/26 24AWG Lead Wire 600V PTFE Insulated Nickel-Plated Copper Wire

Product Overview

When routing high-voltage connections in confined aerospace compartments or vibrating industrial panels, rigidity kills reliability. MIL-W-16878/26 solves that problem. This 600V lead wire combines a nickel-plated copper conductor with tape-wrapped PTFE insulation to deliver exceptional bend recovery and sustained flexibility at temperatures up to 260°C. Designed to NEMA HP-3 Type E requirements, the film-wrapped insulation conforms to tight radii during installation and maintains dielectric integrity through repeated flexing — advantages that extruded PTFE cannot match in dynamic installations.

Available in 24AWG and spanning 32–10 AWG, M16878/26 gives designers the voltage headroom of a 600V system with the routing ease of a thin-film build, all in a medium-wall package that tolerates the thermal abuse of nickel-plated conductors.

Where M16878/26 Adds Value

*Aerospace Cabin and Avionics Wiring
Modern aircraft route hundreds of meters of wiring through tightly packed avionics bays and cargo areas. The supple nature of tape-wrapped PTFE in MIL-W-16878/26 lets technicians snake cables through tight conduits and tight bends without kinking or insulation damage, while the 600V rating handles power distribution needs beyond standard 250V hook-up wire.

*Motion Control and Robotics
Robotic arms, actuator linkages, and servo cables undergo continuous flexing. Extruded insulation cracks under such motion, but the layered PTFE build of M16878/26 flexes cycle after cycle without degradation, making it a practical choice for dynamic power and signal wiring in automation equipment.

*Industrial Sensors Near Heat Sources
Thermocouples, proximity sensors, and pressure transmitters mounted on furnaces, turbines, or exhaust systems need wiring that survives both heat and vibration. The nickel-plated conductor of MIL-W-16878/26 resists thermal degradation at 260°C, and the tape-wrapped insulation handles the mechanical shaking that accompanies high-temperature operation.

*Defense Ground Support and Communication Arrays
Defense electronics in tactical vehicles and field-deployed communication systems face shock, vibration, and temperature extremes. MIL-W-16878/26 meets MIL-Spec construction requirements and its flexible build simplifies field repairs and reconfiguration where extruded wire would be impractical.

*Test Bench and R&D Prototyping
Engineering test rigs require wiring that can be re-routed, re-bent, and re-terminated repeatedly during development. The ease of handling and high-temperature tolerance of M16878/26 make it a favorite in lab environments where designs evolve rapidly and wire performance under stress must be validated.

Tape-Wrapped vs Extruded PTFE:Selection Guide

Choosing between tape-wrapped and extruded PTFE insulation comes down to your application's mechanical demands:

Available Configurations

M16878/26 is stocked in a broad AWG range to cover most 600V lead wire requirements:

Frequently Asked Questions (FAQ)

Get a Quote for MIL-W-16878/24 Wire

Tell us your AWG size, strand type, color, length, and quantity — including AWG size from our 32–10 AWG range. We will respond with pricing, lead time, and datasheet documentation for MIL-W-16878/26 600V PTFE insulated nickel-plated copper lead wire.