Custom Wire Harness Build for the Aerospace Industry

American Precision Assemblers built a custom wire harness from 20 AWG Teflon insulated wire for the Aerospace Industry. This wire harness is currently being used for aircraft bulkhead lighting.

To begin the process of building this product, we first gathered all parts and tools as required. We then used our Komax Gamma 33 machine to cut and laser mark all wires. We also stripped the insulation per customer specifications.

After completing these processes, we then soldered all sub-assemblies and diodes, as well as the fuse holder, onto the harness and then placed heat shrink over all soldered joints. We applied terminals to the ends of the wires and write-on labels to the various connectors. We finally concluded the production of this harness by sliding the backshell onto the wires before pinning the connectors, and then linked all sub-assemblies together.

In order to ensure that the cable harness met IPC/WHMA-A-620 standards and special customer requirements, we performed a comprehensive series of tests, verifying proper wire lengths, component quantities, and wire ID’s. We also ensured that the wire ID’s read left to right.

In addition, we verified that all crimps were correct and of good quality, that all connectors were secure and in position, and that all terminal pins were securely seated. Finally we checked the diodes, LED, and harness to ensure proper quality.

After this comprehensive testing process was completed, we then delivered the finished cable harness to our client’s facility in Tucson, Arizona. The cable harness fulfilled all industry standards – as well as our customer’s high expectations – for performance and quality.