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IND-03 · Aerospace HarnessAerospace
Aerospace
Harness.
Wire harness build for civil aviation, defense, and ground support per MIL-W-22759 wire and MIL-DTL-38999 connector standards. AS9100 audit-ready supply chain, ESS environmental stress screening, salt-fog and altitude qualification. Single-unit through low-rate production.
[IND / AEROSPACE]
Wire specMIL-W-22759
ConnectorsMIL-DTL-38999
WorkmanshipIPC-620 Space
ITAR controlAvailable under NDA
Procurement Friction · WHERE_IT_SLIPS
Where most aerospace programs slip.
PAIN-0101
PTFE wire chafing
MIL-W-22759/11 PTFE wire chafes against an airframe edge after 200 thermal cycles because the routing clamp spacing exceeded MIL-STD-1791 limits.
PAIN-0202
Salt-fog failure at year 1
Connector backshell plating spec was 'cadmium' but received zinc-cobalt substitute — salt-fog per ASTM B117 fails within 96 hours on a humid-coastal airframe.
PAIN-0303
Shield termination drift
Some assemblies have band-strap shield termination; others have direct solder to backshell. EMI test passes on first article, fails on lot 4.
PAIN-0404
Counterfeit connector risk
MIL-DTL-38999 connector arrives with marking that does not match the qualified-product-list manufacturer — engineering rejects entire lot in receiving inspection.
Capability Stack · WHY_VEINWIRE
Where we move the dial.
F-0101
MIL-W-22759 wire stock
/11 PTFE, /16 ETFE, /32 cross-linked ETFE, /41 SPC silver-plated copper variants in stocked inventory.
F-0202
MIL-DTL-38999 connectors
Series I, II, III, IV connectors from Amphenol, TE, Glenair, Souriau — QPL traceable, no broker sourcing.
F-0303
AS9100 audit-ready
Supply chain documented per AS9100 Rev D. Receiving inspection, counterfeit prevention, and material certs on file.
F-0404
ESS environmental screening
Thermal cycling -55°C to +125°C per MIL-STD-810, random vibration 6.06 grms, altitude 70K ft, salt-fog ASTM B117.
F-0505
Band-strap shielding
Glenair band-strap and AccuPunch shield termination per MIL-STD-461 / DO-160 EMI requirements.
F-0606
Frequency-dependent shielding
Foil + double-braid construction with calculated transfer impedance for HF / VHF / UHF avionics.
Spec Table · TECH_PARAMS
Build envelope.
| Wire spec | MIL-W-22759/11, /16, /32, /41, /44, /80, /87 plus M27500 multi-conductor cable. |
|---|---|
| Voltage rating | 600V (28VDC standard), 1000V (270VDC distribution), 3000V (HV ignition). |
| Temperature range | -65°C to +200°C standard. -65°C to +260°C with /11 PTFE construction. |
| Connector families | MIL-DTL-38999 Series I/II/III/IV, MIL-DTL-26482, MIL-DTL-83723, ARINC 600/404, NSX nano-D. |
| Backshell | Glenair, Amphenol, ITT Cannon — cadmium plate, electroless nickel, or anodized aluminum. |
| Shielding | Single foil, single braid, foil+braid, double-braid. Band-strap or solder-sleeve termination. |
| Environmental qual | MIL-STD-810 thermal/vibration/altitude. ASTM B117 salt-fog. DO-160 fluids and EMI. |
| Workmanship | IPC/WHMA-A-620 Class 3 or NASA-STD-8739.4 Space Flight standard. |
| Marking | Hot-stamp per SAE AS50881, laser-etch per SAE AS81531, heat-shrink identification sleeve. |
| Lead time | Prototype 7-14 days (connector sourcing). Production 4-8 weeks with qual reports. |
Fab Protocol · BUILD_PIPELINE
From PO to ship.
PR-0101
Drawing + spec review
MIL-W-22759 variant, MIL-DTL-38999 keying, backshell finish, marking method validated against drawing.
PR-0202
Counterfeit prevention
Connectors and wire sourced from QPL-listed manufacturers or franchise distributors only. Certs verified at receiving.
PR-0303
Form-board build
1:1 plotter-printed form board per SAE AS50881. Routing clamp positions match airframe drawing.
PR-0404
Class 3 / Space assembly
Torque-controlled crimping per M22520 tooling. Shield termination per band-strap or solder-sleeve callout.
PR-0505
ESS screening
Optional ESS thermal cycle, random vibration, altitude, salt-fog per MIL-STD-810 or DO-160 customer spec.
PR-0606
DD-250 / FAI release
First Article Inspection per AS9102 with dimensional report, material certs, qual results. DD-250 acceptance support on DoD contracts.
Use Cases · APPLICATIONS
Where this ships.
Civil avionics harnesses
ARINC 600 / 404 LRU interconnect for cockpit and IFE systems per DO-160G fluids and EMI.
UAV airframe wiring
Weight-optimized MIL-W-22759/32 cross-linked ETFE airframe harnesses for fixed-wing and rotary UAV.
Engine control loom
FADEC and engine sensor harnesses at +200°C zone with PTFE wire and high-temp connectors.
Ground support equipment
Aircraft ground power, fuel-truck, and de-icer cable assemblies with MIL-DTL-26482 connectors.
Defense radio interconnect
VHF/UHF tactical radio cable assemblies with controlled-impedance coaxial and band-strap shield termination.
Missile and munition harnesses
Single-use ordnance harnesses with PTFE wire, hermetic glass-seal connectors, salt-fog qualification.
The biggest aerospace harness risk we see in customer programs is counterfeit-connector entry through brokered MIL-DTL-38999 stock. A connector arrives with the correct QPL marking but failed lots are remarked and resold; the harness passes hipot and continuity on first article and fails salt-fog at month 6. Our standing rule is QPL-listed manufacturer or franchise distributor only — no brokered supply, no exceptions. The 8-10% premium pays for itself the first time you avoid a re-qual cycle.
FAQ · SPEC_QUERIES
Procurement questions.
Do you build to MIL-W-22759 wire specifications?+
Yes — /11 PTFE, /16 ETFE, /32 cross-linked ETFE, /41 silver-plated copper, /44, /80, /87 variants in stocked inventory. Wire sourced from QPL-listed manufacturers (M22759 master spec) only. Receiving inspection verifies certificate of conformance per lot.
Are you AS9100 certified?+
We operate to AS9100 Rev D supply chain requirements with audit-ready documentation. Full AS9100 registration available on customer-program basis at additional certification cost. Receiving inspection, counterfeit-part prevention program, and FAI per AS9102 are standard on every aerospace lot.
Can you perform ESS environmental screening?+
Yes — thermal cycling -55°C to +125°C per MIL-STD-810 Method 503, random vibration 6.06 grms per Method 514, altitude to 70,000 ft per Method 500, salt-fog 96 hours per ASTM B117. Customer specifies screening profile at quote.
Do you handle ITAR-controlled programs?+
Yes under NDA. ITAR registration available for defense and dual-use programs. Engineering files, drawings, and finished goods controlled per 22 CFR 120-130 with restricted-access build cell on customer request.
What workmanship standard do you build aerospace to?+
IPC/WHMA-A-620 Class 3 is our default for aerospace. NASA-STD-8739.4 Crimped, Mechanically Secured, and Soldered Electrical Connections is available for space-flight programs at additional inspection cycle cost.
Sibling specs
Industries served
Capability deep-dives
Engage · RFQ_INTAKE
Quote your aerospace program.
Drop drawings, BOM, or rough concept. Engineering reviews within 4 business hours. NDA available on request.
Back to Industries hubEngage · CTA_002
Quote your aerospace harness program.
Send wire spec, connector callout, ESS profile, ITAR status. Engineering review within 4 business hours under NDA. Response within 4 business hours. No obligation. Drawings stay under NDA.