Overview
XinHarness builds airframe wiring harnesses under segregated aerospace process controls, with certified crimp operators and AS9102 First Article Inspection performed on every new part number before it enters production.
Design & Construction
Wire & Insulation
Wire is built to MIL-DTL-27500 with ETFE or PTFE insulation rated from -55°C to +200°C, sized from AWG 26 up to AWG 4 for power feeders, with print legend and color coding matched to the customer’s wiring diagram.
Shielding & Termination
Single- or double-braid EMI shielding is applied where the drawing calls for it, with 360° backshell termination and crimp-force-monitored terminations to IPC/WHMA-A-620 Class 3 workmanship standards.
Manufacturing Process
Production runs under our AS9100D quality management system, with full material lot traceability from wire spool to finished harness and documented process controls at every operation.
Typical Applications
- Airframe primary and secondary wiring
- Cabin systems and lighting harnesses
- Ground support equipment cabling
- UAV/drone power and signal harnesses
- Engine bay and nacelle wiring
Common installations include Airframe primary and secondary wiring, Cabin systems and lighting harnesses, and Ground support equipment cabling, where flight-critical reliability and stringent weight optimization are the primary design drivers. The same base design can also be adapted for UAV/drone power and signal harnesses and Engine bay and nacelle wiring 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 26 – 4 (MIL-spec wire). Conductor Count: 2 – 150+ circuits. Insulation: ETFE / PTFE, per MIL-DTL-27500. Temp Range: -55°C to +200°C. Voltage Rating: Up to 600V. Shielding: Single/double braid EMI shielding available. Workmanship: IPC/WHMA-A-620 Class 3.
Quality & Certification
Manufactured under AS9100D:2016 and ISO 9001:2015 certification, built to IPC/WHMA-A-620 Class 3 workmanship, with MIL-DTL-27500 wire and full material lot traceability documented per harness.
Customization & Lead Time
Standard lead time for the AS9100D Aerospace Wiring Harness Assemblies is 8–10 weeks prototype (AS9102 FAI), 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 Aerospace Division keeps certified operators and process controls segregated from general industrial production, supporting Tier-1 and OEM aerospace programs. See the Aerospace industry page for full certification scope, 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 AS9100D Aerospace Wiring Harness Assemblies, are manufactured under AS9100D quality management and can be built to MIL-DTL-27500 wire and connector specifications on request.
Every AS9100D Aerospace Wiring Harness 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.
