Technical Overview

Falcon Wire: F-16 Rewiring Program

        All F-16 aircraft manufactured by Lockheed Martin prior to 2003 contain wire harnesses insulated with Aromatic Polyimide. This insulated wire is commonly known as "KAPTON" wire or, MIL-W-81381 wire. Traditionally, wire used in aircraft installation are typically identified by the insulation characteristics and further, is not life cycle specification controlled.
        While in the beginning, KAPTON insulated wire was light weight and possessed great electrical and mechanical properties such as, abrasion and cut-through resistance, high temperature resistant and strength, time has proven to take a toll, making KAPTON susceptible to degradation, breakdown and ultimately, failure.

        lnsulation deterioration occurs for several reasons such as radical temperature exposure, strain, moisture or physical damage. As KAPTON wire ages, it has become stiff, more prone to chaffing, absorbs moisture (hydrolysis) and burns fiercely. Deterioration forms cracks or breaches in the wire's insulation, which leads to spurious electrical signals, noise and electrical malfunctions potentially leading to aircraft fires, loss and worse, personnel endangerment.
        Degradatioin issues of KAPTON wiring in aged F-16 aircraft are becoming a major issue that may prove to be flight critical in certain cases.

        New production F -16 aircraft are no longer using KAPTON wiring. In lieu of KAPTON insulated wire, new production aircraft are installed with TKT (Teflon, Kapton, Teflon) insulated wire. The addition of Teflon to the insulation process is designed to eliminate recurrence of degradation experienced in KAPTON wire. TKT replacement harnesses proposed by InterConnect Wiring, L.L.P. will be identical in configuration to the existing KAPTON harnesses are moved from the existing aircraft. TKT wire harnesses are "Factory New" manufactured to Lockheed Martin specifications and are fit, form and functional direct replacements.