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.
Engineering
Design formanufacturability
A harness drawing is usually finished last and changed most. By the time it reaches a build floor, the routing has moved, a connector has gone obsolete, and the wire gauge was chosen for a load case that no longer applies.
Our team reviews the design before it is quoted rather than after the first article fails. The result is a harness that costs less, builds the same way every time, and installs on the platform instead of on the bench.
Connector and contact selection
Obsolete and long lead connectors identified at quote, with form, fit and function alternates proposed against the mating half rather than in isolation.
Wire, gauge and insulation
Conductor size, insulation type and temperature rating checked against the actual load and environment, because overspecified wire adds cost and bend radius that the routing cannot carry.
Routing and service loops
Bend radius, breakout position and slack reviewed against how the harness is actually installed, so it is not fighting the airframe or the chassis at final assembly.
Branch and splice strategy
Breakouts consolidated and splices reduced where the schematic allows. Fewer splices means fewer failure points and a shorter test.
Termination method
Crimp, solder, ultrasonic weld or solder sleeve chosen for the joint and the volume, not for whatever the print inherited from the last program.
Redlines back to you
Every change is documented and returned for your approval, so the released drawing reflects the harness that actually gets built.
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.
Molding
Overmolding andinjection molding
Where a harness has to seal, take strain, or survive fluid and vibration, a boot and a tie wrap will not hold. Our team molds the transition instead.
The terminated assembly is placed in the tool and material is injected around the joint, forming a single sealed body over the connector rear, the breakout or the splice. There is no adhesive line to fail and no backshell to loosen. Material and durometer are selected for the fluid, temperature and flex the assembly will actually see, and first articles are sectioned to confirm the melt filled the cavity without disturbing the conductors.
Material choice is where most of the performance sits. PVC is the general purpose option and the lowest cost, and it is usually the right answer on commercial and industrial work. PP resists moisture and chemicals at low weight. PBT and POM hold dimension and dielectric strength under heat, which is what a connector rear needs. ABS gives a rigid, stable body where the overmold is doing the job of a housing. TPE and TPU carry the flexible work, with TPU standing up better to abrasion and repeated flex on a moving platform. Viton is what goes on when the assembly sees fuel, hydraulic fluid or sustained high temperature, and it is specified because the environment demands it rather than because it is cheap.
OvermoldingSealed transitions over connector rears, breakouts and inline splices
Insert moldingContacts and hardware molded in place for one piece assemblies
PottingBackshell and cavity potting where the geometry will not take a tool
Strain reliefMolded relief at the transition, sized to the bend radius the harness has to hold
Rigid materialsPVC, PP, PBT, POM and ABS for transitions and housings that have to hold their shape
Flexible materialsTPE and TPU where the transition has to flex, absorb strain and resist abrasion
High resistanceViton for fuel, hydraulic fluid and sustained high temperature exposure
Selection driversFluid and chemical exposure, temperature range, flex life and flammability callout
ToolingPrototype and production tooling, with tool cost quoted separately from piece price
VerificationFirst article sectioning, plus continuity and dielectric test after molding, not before
Specification
Build parameters
WorkmanshipIPC/WHMA-A-620 Class 2 and Class 3
NADCAPAccreditation scheduled for October 2026
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.