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IND-06 · Space TechSpace
Space
Tech.
Vacuum-rated wire harnesses for satellite, launch vehicle, and orbital platform programs. Low-outgassing per ASTM E595, NASA-STD-8739.4 workmanship, ESCC-qualified connectors, full radiation and thermal-vacuum qualification. NewSpace and traditional aerospace customers.
[IND / SPACE]
OutgassingASTM E595
WorkmanshipNASA-STD-8739.4
ConnectorsESCC / MIL-DTL
Vacuum-tested10⁻⁶ Torr
Procurement Friction · WHERE_IT_SLIPS
Where most space programs slip.
PAIN-0101
Outgassing TML > 1%
Cable jacket fails ASTM E595 total-mass-loss with 1.3% — above the 1.0% NASA spacecraft threshold — because the supplier substituted a plasticized PVC for the qualified FEP wire.
PAIN-0202
Thermal-vacuum solder crack
Hand-soldered joint cracks at -150°C in TVAC bakeout because the wire-to-pin transition was solidified under tension, not the strain-relieved profile required by NASA-STD-8739.4.
PAIN-0303
Radiation-induced TID drift
Cable jacket dielectric constant drifts after 50 krad TID exposure in LEO orbit, shifting transmission line impedance and degrading telemetry signal margin.
PAIN-0404
Single string single point of failure
Connector terminal failure on a satellite power harness brings down redundant string because of crimped-wire backfeed — root cause was missing wire diode in fault-isolation design.
Capability Stack · WHY_VEINWIRE
Where we move the dial.
F-0101
Low-outgassing materials
FEP, PTFE, polyimide insulation per ASTM E595 with TML < 1.0% and CVCM < 0.1% certified per lot.
F-0202
NASA-STD-8739.4 workmanship
Crimped, mechanically secured, and soldered electrical connections per NASA spaceflight workmanship standard with full operator certification.
F-0303
ESCC connector stock
ESA ESCC-qualified D-sub, micro-D, nano-D connectors plus MIL-DTL-38999, MIL-DTL-83513 micro-D space-grade.
F-0404
Thermal-vacuum bakeout
TVAC bakeout chamber to 10⁻⁶ Torr at +125°C standard, with thermocouple data logged per cable serial.
F-0505
Radiation-tolerant cables
Polyimide-insulated wire qualified to 100 krad TID with dielectric stability verified post-irradiation.
F-0606
Single-string isolation
Power-bus harness design review for fault isolation and string-redundancy back-feed prevention per NASA fault-tolerance requirements.
Spec Table · TECH_PARAMS
Build envelope.
| Workmanship | NASA-STD-8739.4 (Crimped, Mechanically Secured, Soldered Connections) plus IPC J-STD-001ES Space Addendum. |
|---|---|
| Wire spec | M22759/11 PTFE, M22759/32 cross-linked ETFE, M81381 polyimide-insulated for radiation tolerance. |
| Outgassing | ASTM E595 TML < 1.0%, CVCM < 0.1% per material lot. Certificate per harness serial. |
| Connector families | MIL-DTL-83513 micro-D, MIL-DTL-32139 nano-D, MIL-DTL-38999 Series III, ESCC 3401 qualified D-sub. |
| Temperature range | -150°C to +175°C operational. Bakeout to +125°C for outgassing screening. |
| Vacuum rating | TVAC tested to 10⁻⁶ Torr with bakeout cycle per NASA-STD-6016 contamination control. |
| Radiation tolerance | Polyimide-insulated wire qualified to 50-100 krad TID for LEO and MEO orbital exposure. |
| Voltage rating | 100VDC standard satellite bus. 270VDC high-voltage bus. 28VDC legacy military space. |
| Shielding | Single foil + double-braid construction. Solder-sleeve or band-strap termination per NASA-STD-8739.4. |
| Documentation | FAI per AS9102, material certs per lot, outgassing report, TVAC bakeout log, NASA-STD-8739.4 operator certs. |
Fab Protocol · BUILD_PIPELINE
From PO to ship.
PR-0101
Mission spec review
Orbit profile (LEO/MEO/GEO), TID dose, thermal cycle range, fault-tolerance requirement audited at NPI.
PR-0202
Material qualification
Wire, connectors, sleeving lots qualified per ASTM E595 outgassing. No substitution without re-qual.
PR-0303
ESD-controlled cleanroom build
Class 100,000 (ISO 8) cleanroom with ESD-safe stations. Operators NASA-STD-8739.4 certified, badge logged per joint.
PR-0404
Space-grade assembly
Strain-relieved solder profiles per NASA-STD-8739.4 Section 6. Crimp force per M22520 calibrated tooling.
PR-0505
TVAC bakeout
Thermal-vacuum bakeout at 10⁻⁶ Torr, +125°C, 24-72h customer-specified. Outgassing TML/CVCM verified post-bake.
PR-0606
Acceptance package
FAI per AS9102, outgassing certificate, TVAC log, NASA-STD-8739.4 operator certs, material trace filed per harness serial.
Use Cases · APPLICATIONS
Where this ships.
Satellite power harness
100VDC primary power bus with fault-isolation diode integration and redundant-string back-feed prevention.
Avionics interconnect
Spacecraft avionics bay cable assemblies with micro-D and nano-D connectors per MIL-DTL-83513 and MIL-DTL-32139.
Solar array harness
Photovoltaic string-to-power-conditioning harness with polyimide-insulated wire for radiation tolerance.
Launch vehicle umbilicals
Pad-to-vehicle umbilical cables for telemetry and power during pre-launch with quick-disconnect at lift-off.
CubeSat / SmallSat harness
Compact 1U / 3U / 6U CubeSat internal harness builds with ESCC connectors and low-outgassing materials.
Payload science instrument
Scientific instrument cable assemblies with controlled-impedance signal pairs for telemetry data return.
The space-harness failure mode that ends programs is outgassing — TML above 1% contaminates optical surfaces, solar cells, and detector windows during the first thermal cycle in orbit. Suppliers substitute a plasticized PVC because the FEP wire is on 20-week lead time, and the customer finds out at thermal-vacuum bakeout three months before launch. Our standing rule is ASTM E595 certificate per material lot, no exceptions. The 6-week lead-time premium on qualified wire is cheap compared to a mission re-spin.
FAQ · SPEC_QUERIES
Procurement questions.
Do you build to NASA-STD-8739.4 workmanship?+
Yes — NASA-STD-8739.4 Crimped, Mechanically Secured, and Soldered Electrical Connections is our space-flight workmanship standard, combined with IPC J-STD-001ES Space Addendum for soldering. Operators are NASA-STD-8739.4 certified with badge log per joint.
How do you control outgassing?+
ASTM E595 outgassing certificate per material lot — TML < 1.0%, CVCM < 0.1% verified before the lot enters the cleanroom. TVAC bakeout at 10⁻⁶ Torr and +125°C for 24-72h post-build, with TML re-verified post-bake. Outgassing log retained per harness serial number.
What radiation tolerance do you qualify to?+
Polyimide-insulated wire (M81381) qualified to 50-100 krad TID for LEO and MEO exposure. Cable assemblies tested with dielectric constant and insulation resistance verified post-irradiation. Customer specifies dose profile at quote — qualification testing is performed at partner radiation lab.
Can you handle ITAR-controlled satellite programs?+
Yes under NDA. ITAR registration available with restricted-access build cell, controlled engineering file storage per 22 CFR 120-130. Defense-customer programs and dual-use commercial satellites supported. Material trace and export control documentation filed per contract.
Do you support CubeSat and NewSpace customers?+
Yes — CubeSat 1U / 3U / 6U internal harness builds are common. We work with university teams, NewSpace startups, and traditional primes. Single-unit prototype builds available at 2.5× volume rate. ESCC and MIL-DTL connector inventory supports rapid NPI without long connector lead times.
Sibling specs
Industries served
Capability deep-dives
Engage · RFQ_INTAKE
Quote your space 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 space-grade harness program.
Send orbit profile, TID dose, outgassing spec, connector callout. Engineering review under NDA within 4 business hours. Response within 4 business hours. No obligation. Drawings stay under NDA.