Overview
Weight matters more in drone wiring than in almost any other harness we build. This line balances lightweight wire and connector selection against the reliability expectations of flight controller and payload interconnects.
Design & Construction
Lightweight Conductors
Conductors run AWG 30 to AWG 16 with lightweight ETFE insulation, sized to the platform’s current draw without adding unnecessary mass to power distribution and motor lead harnesses.
Connector & EMI Shielding
Flight controller and payload signal circuits use single-braid shielding where EMI from motor ESCs is a concern, with connector choice matched to the platform’s vibration and quick-disconnect requirements.
Manufacturing Process
Built under our AS9100D-certified process controls, with workmanship to IPC/WHMA-A-620 Class 2 or Class 3 depending on the program’s requirements, and documented material traceability.
Typical Applications
- Multi-rotor drone power distribution harnesses
- Fixed-wing UAV wiring
- Payload and gimbal cabling
- Flight controller interconnects
- Ground control station cabling
Common installations include Multi-rotor drone power distribution harnesses, Fixed-wing UAV wiring, and Payload and gimbal cabling, where flight-critical reliability and stringent weight optimization are the primary design drivers. The same base design can also be adapted for Flight controller interconnects and Ground control station cabling 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 30 – 16. Conductor Count: 2 – 48 circuits. Insulation: ETFE, weight-optimized. Temp Range: -40°C to +105°C. Shielding: Single-braid where required for ESC/motor EMI. Workmanship: IPC/WHMA-A-620 Class 2/3 per program. Connector Options: Quick-disconnect, vibration-rated.
Quality & Certification
Manufactured under AS9100D:2016 and ISO 9001:2015 certification, with IPC/WHMA-A-620 workmanship and material lot traceability documented per program requirement.
Customization & Lead Time
Standard lead time for the UAV & Drone Power and Signal Wiring Harness is 6–8 weeks prototype, 3–4 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
UAV harness work shares process controls and certified operators with our broader Aerospace Division. See 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 UAV & Drone Power and Signal Wiring Harness, are manufactured under AS9100D quality management and can be built to MIL-DTL-27500 wire and connector specifications on request.
Every UAV & Drone Power and Signal Wiring Harness 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.
