Aircraft Wire Harness Manufacturer

As a leading aircraft wire harness manufacturer, Wiringo offers an extensive range of cable assembly options tailored specifically for the aerospace industry.

We stand out through our commitment to innovation and customization among leading aircraft wiring harness manufacturers. 

Clients get high-quality custom airplane wiring harnesses designed to meet their specifications and enhance systems safety and performance.

Benefits of Wiringo’s
Custom Wire Harness Service

Wiringo is committed to delivering top-notch custom wire harness solutions that meet the highest industry standards.

Cost efficiency

Outsourcing saves significant costs by reducing spending on labor, sourcing raw materials, overheads and operational activities.

Fast Turnaround

Receive quotations within 12 hours and benefit from quick production times.

Customized Solutions

Tailored wire harness and cable assemblies to fit your specific project needs.

Innovative Technology

State-of-the-art equipment and processes for precise, reliable results.

Get A Custom Wire Harness Quote Today!

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Why Choose Wiringo?

Wiringo is the ideal choice for aerospace wire harness solutions, combining speed, reliability, and customization to meet the industry’s unique demands.

Fast Delivery

Timely delivery ensures your projects stay on track, with high-quality wire harnesses arriving when you need them most.

Reliable

Rigorous testing and quality control processes guarantee high performance, meeting the strict demands of the aerospace industry.

Diverse Selection

From standard harnesses to custom designs, we offer solutions for various aerospace applications or industrial equipment.

One-on-One Assistance

Our team provides personalized support, working closely with you to understand and fulfill your unique project requirements.

Manu facturing Capa bilities​

Our product versatility and commitment to reliability and quality make us a trusted partner for OEMs seeking innovative and effective writing solutions.

Services

Our harnesses are constructed exclusively with Mil-Spec aviation components, including wire, pins, and connectors. All bundles are expertly tied, wrapped, or encased in expandable sleeving. We provide aircraft wiring harness fabrication for:

  • Audio Panels Intercoms
  • Autopilots
  • EFIS
  • LRU’s
  • Radios
  • Transponders

Process

Before engineering any wire harness, we conduct precise measurements to ensure the correct cutting, splitting, stripping, and marking of all wire and cable assemblies.

We adhere to IPC/WHMA-A-620 workmanship standards as required. Once the product is fully assembled, we apply any necessary labels and mark all clamp positions, ensuring precise placement within a tolerance of ±1/8″.

We conduct a series of in-process measurements and visual inspections to guarantee that the cable wire harness meets rigorous aircraft industry standards.

Customizations

We collaborate with you to create custom harnesses for specialized applications, such as:

  • Onboard camera systems
  • Avionics
  • Communications
  • Missile systems
  • Plug-and-play installation

Pre-built Options

Applications include:

  • Engine, Nacelle, Fuselage, Space, Landing Gear, Ground Support, UAV, and a host of System Wiring Harnesses
  • Strain-Relief, Potted, or Closed Style Backshells (Custom or MIL Spec)
  • Environmentally Engineered Designs
  • Repairable Designs Lightweight, Durable Materials
  • Multi-branched Closed Bundle and Open Bundle designs
  • Ability to braid complex harnesses
  • Cylindrical connector designs, as well as micro-miniature and D-sub
  • Customized and Hybrid Designs
  • Multicolor tracers available
  • In-house Over-Braiding with Nomex®, Metal, Kevlar®, PEEK™, or other protective materials

Safety Testing

The Wiringo team will customize our thorough testing processes to meet the needs of your particular project and industry.

Certifications

We specialize in fabricating multi-branched electrical wiring harnesses with IATF 16949 and ISO 9001 certifications. Our production and inspection processes comply with IPC/WHMA-A-620 standards.

Samples and Prototyping

Tested cable assemblies are created to verify functionality and manufacturability, ensuring they perform as designed.

Flexible Order Quantities

Our advanced aircraft wire harness fabrication process handles small and large orders while maintaining top quality.

Harness and Cable Assembly Products

At Wiringo, nearly every feature of a wiring harness and cable assembly can be tailored to the application, so clients can choose elements that streamline airplanes.

Closed Bundle Wiring Harnesses

These harnesses are engineered to efficiently organize and protect wires, minimize interference, and enhance durability in various applications.

Open Bundle Harnesses

Open bundle harnesses are accessible, making them ideal when repairability is essential. This design is commonly used for signal and communication harnesses and is found on gas turbine engines, nacelles, and airframe fuselages.

Overmolded Wiring Harness

This type of harness features a protective oversold, providing added strain relief and environmental protection, ensuring reliable performance in challenging conditions.

Hybrid Harnesses

In addition to jacketed copper wire and cylindrical connectors, we can incorporate micro-miniature connectors, CAT 5 & 6 USB, D-sub, and impedance cables.

Aircraft Applications

Wiringo delivers tailored wire harness solutions for a wide variety of applications.

Commercial

Military

Private

Aerospace and Satellites

Helicopters

We Partner With Top Manufacturers and Suppliers

By partnering with reputable suppliers, we maintain a robust inventory of high-quality interconnect materials, ensuring our clients receive top-tier wire harness products.

Get Your Free Sample!

Enjoy a free sample worth UP TO $100!
Explore our custom services now. Email us at [email protected] for more details.

What Our Customers are Saying

See what thousands of happy customers have to say about Wiringo’s commitment to product quality and customer service

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Frequently Asked Questions

What is the typical lead time for custom wire harnesses?

Depending on design complexity, lead time is usually 4 to 6 weeks, with expedited options for urgent requests.

What materials do you use in your wire harnesses?

We use high-quality, durable materials selected for aerospace performance, including various MIL Spec aviation wires, cables, and connectors.

How do you ensure exceptional product quality?

We enforce strict quality control measures throughout manufacturing, including inspections and adherence to established standards.

Indust ries We Serv e

We manufacture custom wiring solutions to meet the unique demands of various industries, ensuring quality, reliability and innovation.

automobile industry

Automotive

We have high-performing automotive wire harness solutions that meet rigorous demands and ensure safety and reliability in every vehicle.

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Military

Our military wire harnesses are highly durable and capable of critical support for mission-ready equipment.

wiring

Robotics

Our advanced robotics wiring solutions offer better functionality, efficiency, and seamless operations in automated systems.

automobile industry

Medical

Our harnesses ensure strict compliance with medical safety and performance standards, maintaining precision and reliability in critical applications.

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Aerospace

We deliver lightweight, strong, and resilient wiring harnesses for the aerospace industry while meeting the aviation industry’s stringent safety and performance standards.

wiring

Construction

We build harnesses that withstand harsh environments and perform well in heavy machinery and equipment.

automobile industry

Agriculture

We build robust harnesses for the agriculture industry so that heavy machinery can deliver high performance in demanding outdoor conditions.

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Lighting

We offer customized solutions, ensuring performance and safety in lighting conditions.

wiring

Electronics

We design versatile and precisely designed products that support various applications with reliable connectivity.

Looking for The Best
Custom Wire Harness &
Cable Assembly Service?

Fast Turnaround Time

At Wiringo, we ensure that custom wiring harness solutions are tailored to your needs, with quotations delivered within 12 hours to keep your projects on track.

Certified Quality Assurance

Our factory is ISO9001 and IATF16949 certified, guaranteeing the highest standards of quality, reliability, and compliance for all custom wiring harness and cable assembly services.

One-Stop Custom Solutions

We offer a complete, one-stop solution for all your wiring harness needs, from design to manufacturing, ensuring you get exactly what you need for your project.

Tailored High-Quality
Wire Harness and Cable Assemblies That Are Secure and Reliable.

At Wiringo, we make it possible for you to optimize and produce your dedicated wiring harness and cables with sturdy parts. We also ensure that all your goods pass strict process management. That way, teaming up with you is easier to help grow your business rapidly.

Get Quality
Custom Wiring Harness and Cable Assembly today.

At Wiringo, we make it possible for you to optimize and produce your dedicated wiring harness and cables with sturdy parts. We also ensure that all your goods pass strict process management. That way, teaming up with you is easier to help grow your business rapidly.

Custom Wiring Harness

Wiringo has over ten years of experience producing custom wiring harnesses. During that time, we have delivered high-quality custom wiring for every client.

Choose Wiringo’s Aircraft Wiring Harnesses

Partner with Wiringo for reliable, responsive service and exceptional performance in demanding environments. Request a quote today!

Get Your Free Sample!

Enjoy a free sample worth UP TO $100!
Explore our custom services now. Email us at [email protected] for more details.

Electrical harnesses are a staple in modern electronics and the backbone of the auto industry.

Without it, the systems inside these machines wouldn’t be automatic.

However, technical progress has allowed the use of adaptable and robust wire harnesses useful in other complex industries, like the aerospace or aviation industry.

Let’s see how the aircraft wire harness evolved during the period and how they are used now.

Get Your Free Sample!

Enjoy a free sample worth UP TO $100!
Explore our custom services now. Email us at [email protected] for more details.

Innovations in Aircraft Technology 

Flying in today’s high-tech world may seem like a mundane experience, something that most of us experienced before.

However, airplane technology has progressed a lot thanks to its rich history.

When planes first took to the skies, aerodynamics was the key to getting from point A to point B.

Thermal airships, or hot air balloons, were the first aircraft to carry humans.

However, aerodynamics and motor technology advancements in the early 20th century made powered-controlled flights increasingly common.

Similar to modern airplanes, these early models were developed by 1909.

Aerospace engineering has advanced through the years, with more potent aircraft engines and new improvements in aircraft wiring harnesses.

Aircraft and the aviation sector, as it exists now, would not exist without the technological breakthroughs it has experienced.

At the same time, an aircraft wire harness serves the same primary function as any other wiring system and the innovations it has brought to the aerospace industry.

Caption: Hydraulic lines inside the aviation system

Why Do Aircraft Have Wiring Harnesses?

There was no such thing as a wiring harness in the early days of airplane development since electrical systems did not exist.

They had to move the flying control surfaces using only structural parts, ropes, and pulleys.

Metal cables soon replaced the ropes; even today, many planes don’t “fly by wire,” instead relying on cables and pulleys.

Eventually, an airplane designer decided to wire in a light and put in a switch, battery, and bulb.

He connected these parts with cables, creating the airplane’s first electrical lighting system.

Since this system only required a small number of wires, harness manufacturers put them individually in safe locations.

Subsequently, other architects came along and incorporated even more electrical infrastructures.

Aircraft mechanics eventually realized that they were installing cables one at a time despite groups of wires flowing from one part to another.

Moreover, they needed more wires for each additional device.

The duration of this setup process was lengthy.

Mechanics began grouping and routing cables together in bundles to increase productivity.

The aviation industry took notice and deemed this a worthwhile development.

After conceptualizing the wire bundles as a whole, they assembled them there.

With this, they created the first wire harness.

Aircraft wire harnesses serve this purpose.

Shot wire tubes inside the wall

Caption: Shot wire tubes inside the wall

Get Your Free Sample!

Enjoy a free sample worth UP TO $100!
Explore our custom services now. Email us at [email protected] for more details.

The Functionality of an Aircraft Wiring Harness

Similar to how a car’s harness directs electrical impulses, a plane’s wiring harness does the same for the complete aircraft.

The engine, landing gear, wings, and fuselage are only some of the functions it regulates.

Wire harnesses typically have a great deal going on inside of them.

Miles of cables, wires, and thousands of individual parts make up an airplane wiring harness.

In addition, they all have to function together to keep the plane flying smoothly.

Today’s aircraft manufacturers must also keep up with rapidly developing technologies and upgraded aircraft wiring connections to support cutting-edge additions.

In addition to improving efficiency in production and manufacturing, an aircraft wire harness also makes it easier for mechanics to identify and repair planes experiencing technical difficulties.

Wire harnesses eliminate the need to install the electronic systems of a humongous plane separately.

When problems arise and maintenance is required, mechanics must identify the affected component to fix it.

Three Categories of Parts in an Aircraft Wiring Harness

The aircraft you will put it in is a significant factor in determining the specific elements and components of the wiring harness when designing a plane that meets military specifications; there are many things that you have to take into account.

These are the three types of airplane components.

Standard Components

In a plane’s electrical system, the military will often have the final say over the components known as MIL-SPEC (military standard).

The letters M or MS appended to the beginning of the serial number designate them as a military issue.

Some are prefixed with the letters NAS to show that they conform to the National Aerospace Standard.

A few standard component prefixes exist, but these two are the most prevalent in a military plane’s wiring harness.

On the other hand, the military and many other aerospace sectors.

Nonetheless, the government must certify specific manufacturers before you can consider them as authorized suppliers.

Non-Standard Components

Non-standard components are frequently variants of commercially available components that meet a slightly different military standard.

Original equipment manufacturers can dictate the criteria for non-standard components (OEM).

Original Equipment Manufacturers also have the option to permit which of their suppliers to produce non-standard components.

However, the cost of a non-standard element for an airplane harness tends to be higher since so few exist.

Commercial, Off-the-Shelf Components (COTS)

Manufacturers mass-produce COTS components in response to market research and consumer demand.

The producer can improve the design of the components without permission from the government or the defense.

A manufacturer can create their parts and assign them unique part numbers.

As with the other two components, you can purchase COTS options from vendors at a reduced cost.

However, manufacturers have exclusive power over the distribution of COTS components, allowing them to set prices and determine market share.

Furthermore, they have the freedom to alter or amend any requirements.

However, it might cause a problem as it becomes essential to source new components for a plane’s wiring harness due to a depleted supply.

Aircraft Wiring and Connection

Aircraft wire harnesses have wiring that is miles long.

Therefore, you need to plan and structure them precisely to prevent problems during and after construction.

Thus, the first step in any design process is the creation of a schematic in CAD software. It serves as a guide for subsequent construction.

Insulating materials used to be a one-size-fits-all affair, but nowadays, many options are available to meet various needs.

The signal you send, and the system’s electricity dictate which wires are used. Wire insulation also shifts with these variables.

It would also help to label the wires so that assembly and repairs don’t mix them up.

However, when picking a connector, you should remember these three things.

The number of connections that the connector can accept should come first.

The second factor is the thickness of each wire, and the last is the type of wire to enter the aircraft connector.

Conclusion

The aircraft wire harness is based on different wires and connectors.

Moreover, other standards, non-standard, and COTS parts make the harness complete and functioning.

While choosing the elements, you need to look into your requirements.

Then you will get to design the schematic using CAD software.

At Cloom, we offer wiring harnesses and cable assemblies to make your connection safe and reliable.

Get Your Free Sample!

Enjoy a free sample worth UP TO $100!
Explore our custom services now. Email us at [email protected] for more details.

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