MIL-SPEC 22759/16 Wire Selector

Find the right wire size for your aerospace, military, and motorsport applications quickly and easily.

Designed using MIL-SPEC 22759/16 standards for aerospace, military, and motorsport applications. The calculator includes temperature derating and bundle derating factors.
Values are automatically saved locally for future reference.

Wire Selector

A
Enter the maximum current your device will draw in amperes. Range: 0.1 to 300A.
ft
Enter the total length of the wire run in feet. Range: 0.1 to 500 ft.
V
Enter your system voltage in volts. Range: 0.1 to 48V.
wires
Enter the number of wires in the bundle. Range: 1 to 20 wires.
Adjust the ambient temperature where the wire will operate. Range: -65°C to 150°C.
Select your industry for specialized recommendations.
Select the type of device being powered for device-specific recommendations.

Recommended Wire Size

Your recommended wire size based on MIL-SPEC 22759/16 standards:
MIL-SPEC STANDARD
-- AWG
--
--% Voltage Drop
MIL-SPEC Standard (150% Factor)
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MOTORSPORT STANDARD
-- AWG
--
--% Voltage Drop
Meets Motorsport Standard
UNSAFE: Below Minimum
Motorsport Standard (130% Factor)
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UNSAFE Reference
-- AWG
--
--% Voltage Drop
Meets Minimum Safety
UNSAFE: Below Minimum
For Reference Only (100% Factor)
Not recommended for use
Recommended Fuse Size (125%)
--

Amperes

UNSAFE: Fuse Exceeds Wire Ampacity
Sizing Legend

Base Current: -- A

The actual peak current draw of your device/circuit

Wire Sizing (150%): -- A

Best practice wire sizing per MIL-W-5088 for aerospace/military/motorsport applications. Provides additional headroom for thermal management and future load increases.

Fuse Sizing (125%): -- A

Minimum fuse sizing per MIL-SPEC standards. Prevents nuisance tripping during normal operation while maintaining proper circuit protection.
Wire Gauge Comparison
Wire sizes shown proportionally: smaller AWG number = larger wire diameter
Low Stress (<50%)
Medium (50-75%)
High (>75%)
Aftermarket Industries PR40
PR40 Relay with 2-Way LED Fault Detection
--
Meets 150% Safety Meets 125% Safety Below 125% Safety
--
Technical Specifications:
  • 2-Way Fault Detection LED
  • Surge Protection Diode
  • Vibration & Shock Resistant to 10G
  • IP50 Rated
  • -40c to 85c Temperature Range
  • 5ms Switching Response Time
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40A continuous
12V system
IP50 rated
Temperature Impact Analysis

This chart illustrates how ambient temperature affects wire resistance and performance. Higher temperatures increase resistance, reducing current-carrying capacity.

Temperature Impact: Analysis will appear after calculation.
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Application Insights
Applicable Standards
About these standards: These industry specifications are compatible with or reference MIL-SPEC 22759/16 wire specifications. Use these standards for cross-reference in technical documentation, compliance verification, or when sourcing alternative components for your aerospace, military or motorsport project.
Important: This calculator provides reference values based on MIL-SPEC 22759/16 wire standards. Always consult with a qualified engineer and refer to the appropriate specifications for aerospace, military, and motorsport applications.

Updated April 14, 2025

What's New
  • Updated MOTORSPORT STANDARD classification from 135-149% to 130-149% threshold
  • Updated UNSAFE classification to 100-129% (previously 100-134%)
  • Enhanced safety classifications for more accurate industry standards
  • Fixed edge case in fuse safety calculations for 25-26A current draws
  • Improved exception handling in safety recommendation engine
  • Enhanced responsive design for all screen sizes