Discrete wire harnesses
Point to point builds on formboard, from a handful of circuits up to full platform looms.
Wire HarnessAssembly
Discrete wire, cable and overbraided harnesses built to IPC/WHMA-A-620 Class 2 and Class 3. Formboard build, overmolding, verified crimps, and continuity and dielectric test on every assembly before it ships.
Overview
One harnessone part number
Last to be designed, first to get installed: our team gets it and will deliver to fill the timeline gaps.
A harness is where a bill of material gets long. Connectors from one supplier, contacts from another, wire and sleeving from a third, and a build that only starts once the last of them shows up.
Our team buys the whole list. The harness comes back built to your print, tested, marked and bagged, against one purchase order and one point of contact.
Cable assemblies
Coax, twisted pair, ribbon and multiconductor, terminated to the connector on your callout.
Shielded and overbraided
Expandable sleeving, metal overbraid and shield terminations for EMI sensitive runs.
Molded and potted
Overmolded transitions and potted backshells where the assembly has to seal and stay sealed.
Panel and box builds
Harnesses installed into the enclosure, with components mounted and wired in place.
Repair and rework
Existing harnesses brought back to standard, with the failure documented rather than buried.
Process
From wire listto tested harness
Print and wire list review
Our team reads the drawing before quoting it. Missing callouts, obsolete connectors and routing that will not build get flagged back to you, not discovered on the floor.
Sourcing and kitting
Connectors, contacts, wire, sleeving and hardware bought to the print, including long lead and obsolete parts. Counterfeit mitigation consistent with AS5553 and AS6081.
Cut, strip and terminate
Automated cut and strip, crimping with calibrated tooling. Crimp height and pull force are checked against the IPC/WHMA-A-620 tables and recorded.
Formboard build
Every harness is laid up on a board built from your drawing, so the second unit measures the same as the first and the four hundredth measures the same as both.
Protection and marking
Braid, convolute, heat shrink and potting as the print calls for. Wire and assembly marking applied, then verified against the drawing.
Test and delivery
Continuity, dielectric withstand and insulation resistance before anything ships. Delivered loose, kitted to the line, or already installed in the enclosure.
Verification
Nothing shipsuntested
A harness fails at the crimp, and a bad crimp looks the same as a good one from the outside. So nothing leaves here on a sample plan.
Continuity
Every circuit checked against the wire list. Opens, shorts and miswires are caught here rather than at your integration bench.
Dielectric withstand
High potential test at the voltage your print calls for, with the result recorded against the serial number.
Insulation resistance
Megohm testing between conductors and shield, so marginal insulation surfaces before the assembly leaves.
Pull and crimp
Destructive pull tests on setup samples and at interval through the run, with crimp height logged for the lot.
Specification
Build parameters
WorkmanshipIPC/WHMA-A-620 Class 2 and Class 3
Assembly typesDiscrete wire, cable, overbraided, molded and potted
ConnectorsMIL-DTL-38999, MIL-DTL-5015, MIL-DTL-26482, commercial and custom
Wire and cableM22759, M27500, M16878 and commercial equivalents
TerminationCrimp, solder, ultrasonic weld and solder sleeve
ShieldingMetal overbraid, conductive sleeving and shield terminations
ProtectionExpandable sleeving, convolute, heat shrink and potting
TestContinuity, dielectric withstand and insulation resistance, every assembly
VolumePrototype, low rate initial production and full rate
TraceabilityLot and serial level, test records traveling with the shipment
Contact us with your harness drawing
A drawing, a wire list and a quantity is enough to start. Our team will come back with what it can take off your plate.