Overview
Cockpit and avionics bay interconnects run higher circuit density in tighter spaces than general airframe wiring, and typically terminate into circular connector families rather than open pin-and-socket blocks. This line is set up specifically for that interconnect work.
Design & Construction
Connector Systems
Terminations are built around MIL-DTL-38999 circular connectors with environmental-sealing grommets, using qualified crimp tooling per contact size and documented pull-test records for each connector cavity.
Shielding & Routing
Double-braid shielding with 360° backshell grounding is standard for avionics signal runs, and harness routing/branch layout is built to the customer’s installation drawing to minimize EMI coupling in the avionics bay.
Manufacturing Process
Assembly runs under the same AS9100D-certified process controls as our airframe harness line, with certified operators, connector pull-force testing, and full lot traceability from wire spool to finished cable.
Typical Applications
- Cockpit instrument panel interconnects
- Flight control system cabling
- Communication and navigation avionics
- Data bus (ARINC/MIL-STD-1553) cable assemblies
- Avionics bay rack-to-rack interconnects
Common installations include Cockpit instrument panel interconnects, Flight control system cabling, and Communication and navigation avionics, where flight-critical reliability and stringent weight optimization are the primary design drivers. The same base design can also be adapted for Data bus (ARINC/MIL-STD-1553) cable assemblies and Avionics bay rack-to-rack interconnects with minor changes to connector type or cable length.
Technical Specifications
Standard configurations are available with the following technical specifications; custom configurations outside these ranges can be discussed with our engineering team. Wire Gauge: AWG 24 – 12. Conductor Count: 2 – 96 circuits. Connector Series: MIL-DTL-38999 circular connectors. Insulation: PTFE / ETFE. Temp Range: -55°C to +200°C. Shielding: Double-braid, 360° backshell termination. Workmanship: IPC/WHMA-A-620 Class 3.
Quality & Certification
Built under AS9100D:2016 and ISO 9001:2015 certification, with MIL-DTL-27500 wire, MIL-DTL-38999 connector systems, and IPC/WHMA-A-620 Class 3 workmanship on every unit.
Customization & Lead Time
Standard lead time for the MIL-DTL-27500 Avionics & Cockpit Cable Assemblies is 8–10 weeks prototype, 4–6 weeks production. Connector type, cable length, and conductor configuration can be customized to match your exact application, including MIL-spec connector alternatives and shielding options for specific avionics or airframe integration requirements. Contact our engineering team with your drawings or requirements for a project-specific quote.
Why XinHarness
Our connector-focused avionics work runs alongside our broader airframe harness capability under the same certified quality system. Read more on the Aerospace industry page, or request a quote for your project. For related technical background, see our article on the impact of extreme temperatures on wire harness performance.
Frequently Asked Questions
All aerospace harnesses, including the MIL-DTL-27500 Avionics & Cockpit Cable Assemblies, are manufactured under AS9100D quality management and can be built to MIL-DTL-27500 wire and connector specifications on request.
Every MIL-DTL-27500 Avionics & Cockpit Cable Assemblies unit undergoes continuity, insulation resistance, and dielectric withstand testing, with additional environmental and vibration testing available for flight-critical applications.
Yes. Connector types, wire gauge, shielding, and routing length can all be customized to match your specific airframe and installation requirements — contact our engineering team with your drawings or specifications.
