AS9120B, ISO 9001:2015, AND FAA AC 0056B ACCREDITED

Designing Electromagnetic Components for Aerospace Applications

Aviation is an ever-demanding industry, and to meet its demands, it must uphold speedy development processes, especially in the electromagnetic field. As different types of electrical systems and components in an aircraft are of the electromagnetic variety, their development coincides with providing the aerospace industry with ever-improving components capable of meeting precise requirements.

The electronic system of modern aircraft combines magnetic elements with alternators, generators, inverters, rectifiers, and transformers that work together to help generate and distribute electric power. Receiving systems use this electricity to control altitude, monitor flight paths, and track locations. As such, they all play a vital role in keeping these aerospace systems functioning and assisting in successful flight operations.

Aerospace manufacturers have different requirements when designing avionic equipment because each airplane has unique specifications. The electromagnetic components are tailored to suit the needs of various types of aircraft. Weight, space, and size can make an ideal component for one type versus another. Thus, it is important that each electromagnetic component is individually integrated to accommodate specific electrical systems. Magnetic components are valuable throughout various military applications and can be found in missile defense equipment, jamming or signal-protecting equipment (infrared light; radio), and radar. For example, Electromagnetic Aircraft Launch Systems (EMALS) help aircraft launch from carriers with the aid of electromagnetic systems.

The right choice of components can make or break an airplane. The electromagnetic spectrum is home to three main parts: transformers which provide electricity at high voltage; resistors which reduce heat levels in various devices such as motors and generators found throughout aircraft systems like cabin air compressors (CACs), ram-air turbines (RAT), integrated starter alternators/generators ISAs /ISGs, auxiliaries power units (APU). It is important for engineers to design these pieces carefully because if there are losses in efficiency, performance will suffer significantly.

Unique Aerospace Magnetic Components:

Air-Core Conductors: Air-core conductors are a special kind of electromagnetic part due to their innovative design. They are lighter than other components with similar designs, especially those that include extra materials which add unnecessary weight during flight time. Air-core conductors resemble light, fibrous strands, and can be applied on materials like PTFE and glass, making them easier for aerospace applications. When constructing aerospace products, every ounce counts in terms of weight distribution, making conductive wires optimal choices. These conductors are also designed and produced specifically for very-high-frequency (VHF) and ultra-high frequency (UHF) radio frequency applications.

Isolation Power Transformers: Ionizing radiation and electrical shorts can be a huge problem for those who work with aerospace systems. They are vital to the safety of everyone on board an aircraft, and malfunctions in these systems can pose a hazard for anyone near their operating location. Isolation Power Transformers protect electronics by separating primary (non-power) windings from secondary ones that carry high voltage current needed during certain flight conditions, protecting against potential damages.

Transformer Rectifiers: Transformer rectifiers are an efficient means of conducting electricity. They operate on 3-phase AC power sources and have been used in many aerospace systems due to their capability of efficiently handling large amounts of electricity with low distortion—even at higher voltage levels. Transformer rectifiers come in different sizes depending upon how much current is needed, which includes a rating of 10 amps to 400+ amperes (or milliamps). There are also 12 or 24 pulse models available for those who want more control over their output waveform, but either way, this will provide clean DC volts up to 28V. They are also highly effective, providing an 88% efficiency rating.


The aerospace industry is in the process of moving away from traditional, centralized hydraulic systems and toward electrification to power its fleets. This transition requires an ever increasing reliance on magnetic technologies to control altitude, monitor flight paths, and track locations.

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