Aerospace Wire Harness Manufacturing Assembly
In the high-stakes world of aerospace, wire harnesses aren’t just components — they’re literal lifelines. At OurPCB, we’ve spent years perfecting these critical systems for aviation, defense, and space applications where even the smallest failure can lead to disaster. Our harnesses don’t just meet specs — they’re crafted with an obsessive level of precision that most manufacturers would find excessive.
We’ve assembled a team with decades of hands-on aerospace electronics experience because we understand what’s really at stake. Reliability isn’t some nice-to-have feature — it’s absolutely non-negotiable when lives and multi-million dollar missions hang in the balance. That’s exactly why we test every harness using procedures that would seem ridiculously thorough in any other industry. When failure simply isn’t an option, our verification process delivers the one thing aerospace engineers need most: absolute confidence in every connection.
What are Aerospace Wire Harnesses?
Aerospace wire harnesses are essentially the nervous system running through aircraft and spacecraft. They’re not just fancy wire bundles — they’re meticulously engineered networks that route power and critical data to everything that keeps these machines in the air or orbit. What makes them special is their ability to survive conditions that would destroy regular wiring. We’re talking about wiring that functions perfectly through extreme vibration, temperature swings from -65 °F to 350 °F, and even high-altitude radiation.
Our manufacturing process has zero tolerance for errors because the consequences are too severe. Every component from the smallest connector to the main power cables must meet specifications that would seem ridiculous in consumer electronics. But when you’re building something that will carry astronauts to the ISS or keep a 787 with 300 passengers safely cruising at 35,000 feet, those standards suddenly make perfect sense.
PCB Manufacturing Process
What are the Benefits of Aerospace Wire Harnesses?
The benefits of aerospace wire harnesses are their greater reliability in extreme conditions, superior weight optimization, and compliance with a higher degree of standards. Our specialized manufacturing approach ensures you receive high-quality wire products that maximize performance while minimizing potential points of failure.
- Each harness application is built with specialized materials designed to withstand temperature extremes from -65 °C to +200 °C without performance degradation.
- Our rigorous testing protocols simulate flight conditions to verify operational integrity under stress, ensuring systems maintain functionality during critical operations.
- Strategic material selection and routing design reduce harness weight by up to 30% compared to standard commercial solutions.
- Our engineering team specializes in lightweight aerospace-grade conductors and insulation that maintain electrical performance while minimizing mass impact.
- Every harness manufacturer must follow ISO 9001, and IPC/WHMA-A-620 requirements, which we consistently meet.
- Full material traceability and batch tracking ensure regulatory compliance and facilitate FAA certification.
Superior Field Reliability
- IP67-rated connectors resist complete dust ingress and withstand water immersion up to 1 m for 30 minutes.
- Marine-grade insulation materials provide chemical resistance against fertilizers, pesticides, and fuel exposure.
Extended Equipment Lifespan
- Temperature-resistant components function reliably from -40 °C to 105 °C, preventing heat damage in engine compartments.
- Reinforced strain relief and secure terminal connections prevent failures from constant diesel engine vibration.
Simplified Troubleshooting
- Color-coded wiring with clear detail reduces diagnostic time by up to 60%.
- Comprehensive documentation includes wiring diagram specifications specific to your tractor model.
Customization Options
- Exact-fit design ensures perfect compatibility with your specific Farmall or Cub Cadet restoration.
- Additional capacity options accommodate future implements or aftermarket electrical accessories you may add later.
Why Choose OurPCB for Aerospace Wire Harnesses
When selecting a partner for your aerospace cable assemblies, experience and attention to detail make all the difference. Our specialized approach delivers superior results for the most demanding applications.
- Our team brings decades of combined expertise in aerospace electrical systems to every project we undertake.
- We’ve successfully delivered wire harness solutions for commercial aviation, military aircraft, satellite systems, and ground support equipment.
- 100% electrical testing on every harness verifies perfect functionality before shipment.
- Automated optical inspection and X-ray examination of critical connections ensure zero defects in critical applications.
- Complete control over the manufacturing processes from design through testing ensures consistency.
- Our facilities in Thailand and the Philippines maintain all required aerospace certifications and security clearances for defense projects.
- Dedicated aerospace technicians provide design optimization recommendations that improve performance and reduce costs.
- Rapid prototyping capabilities allow for design validation before full production, reducing development time and risk.
PCB Assembly Services
OurPCB offers comprehensive PCB assembly solutions that complement our work as aircraft wire harness manufacturers. Our assembly processes deliver the same commitment to precision and reliability that defines our aerospace work, ensuring integrated systems that perform flawlessly in critical applications.
We employ cutting-edge Surface Mount Technology for creating compact, high-performance electronic assemblies essential for engine and flight control systems. Our advanced manufacturing equipment achieves component placement accuracy to 0.01 mm, ensuring reliable performance even under extreme conditions.
We provide flexible assembly options tailored to your project requirements. Whether you prefer to supply your own aerospace-grade components or trust our OEM sourcing expertise for a complete turnkey solution, we maintain the highest quality standards throughout the process.
Our custom capabilities are ideally suited for specialized aerospace electronics requirements. We handle complex, multi-layer designs with mixed-technology assembly, combining surface mount and through-hole components to achieve the perfect balance of high-performance and durability for flight-critical systems.
When development deadlines are critical, our quick-turn assembly services deliver exceptional quality without compromising reliability. We maintain dedicated capacity for expedited aerospace projects while still performing the comprehensive testing and inspection required for certification.
Our assemblies meet or exceed IPC Class 3 requirements for high-reliability electronic systems where continued performance is critical. This exacting standard ensures your PCBs will function reliably in demanding environments encountered during flight operations and space missions.
We specialize in the precision placement of advanced IC packages commonly used in aerospace computing systems. Our state-of-the-art equipment and skilled personnel are certified for handling complex BGAs, QFNs, DFNs, and other fine-pitch components that require perfect alignment and connection integrity.
Millions of business and innovators use OurPCB
Technical Capabilities
Our innovative aerospace wire harness manufacturing facility is equipped with specialized tools and equipment designed specifically for high-reliability applications. From automated wire cutting and processing to advanced crimp force monitoring and pull-testing equipment, our technical capabilities ensure consistent quality across every production run.
We maintain an extensive inventory of aerospace-grade electrical wires, connectors, terminals, and protective components from manufacturers approved for aviation and defense industries. All materials are lot-tracked and tested to ensure compliance with applicable specifications.
The processes include but not limited to the following:
- Wire Gauge: 40AWG-120mm²
- Production Capacity: 10,000 pieces/hour
- Wire Cutting Service: 15-50,000mm, any length as required.
- Wire Stripping Service: Strip the insulation/jacket in required length from the end or retained, then twist or tin the end.
- Wire Marking Service: Labels with Series number, Part number, Date code, etc.
- Label Types: Heat shrink tubing label, Waterproof self-adhesive label, Custom labels.
- Wire Ends Treatment: One or several wires crimped with a terminal, soldered to kinds of connectors/electronic components.
Custom Wire/Cable Service:
- Wire/Cable types
- Wire gauge
- Wire/Cable length
- Insulation/Jacket color
- Core numbers etc.
Custom Cable Assembly Capacities:
All kinds of cable assemblies including
- Electrical cable assembly
- Coaxial cable assembly
- Multi-core cable assembly
- Connector to board cable assembly
- Automobile communication cable assembly
- Power transmission cable assembly
Mon-Fri: 24 hours,
Sat: 9am-6pm, GMT+8
Reach us at
[email protected]
24 hours online
+86-199-30589219
Mon-Fri: 24 hours,
Sat: 9am-6pm, GMT+8
Aerospace Wire Harness Manufacturing Assembly FAQs
What certifications does OurPCB maintain for aerospace wire harness manufacturing?
OurPCB maintains AS9100 aerospace quality certification, ISO 9001 quality management certification, and IPC/WHMA-A-620 workmanship certification specifically for cable and wire harness manufacturing. Our facility is also ITAR registered for defense projects and complies with DFARS requirements for military applications.
How does OurPCB ensure traceability for aerospace wire harnesses?
We implement comprehensive material traceability protocols that track every component from receipt through manufacturing and delivery. Each wire, connector, terminal, and protective component is documented with manufacturer information, lot numbers, and test results. This traceability chain supports airworthiness certification and provides complete documentation for regulatory compliance.
What testing procedures are used to verify aerospace wire harness quality?
Every aerospace harness undergoes 100% electrical testing including continuity verification, insulation resistance measurement, and dielectric strength testing where applicable. We also perform mechanical tests including pull testing on crimp connections and environmental simulation for temperature extremes and vibration resistance. All test results are documented and included with harness deliveries.
