Custom Aerospace Wire Harness for Avionics, Power, and Engine Control Systems
Aerospace wire harnesses run electrical signal and power through flight control systems, engine assemblies and avionics across the fuselage and landing gear zones.
WellPCB manufactures custom wire harnesses with mil-spec connectors, shielded coaxial and fiber optic cable and ISO9001 certified manufacturing for precision routing and modular installation in the aerospace industry.
Our aerospace wire harness solutions meet the highest quality standards for conductivity, EMI shielding and crimp integrity and support coax and data bus interconnect products for flexible electrical system layouts.
- Custom wire harness assemblies for flight deck, engine and cabin systems
- ISO9001 aerospace harness manufacturing with full electrical and dimensional test coverage
- Cable assemblies with coaxial, fiber optic and Ethernet connectivity options
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ISO9001 ISO13485
ISO14001
IATF
16949
IPC-A-610H International
Certification
Fully Automated
AOI Inspection
Aerospace Wire Harness Manufacturing for Certified Aerospace Systems
As a trusted custom wiring harness manufacturer, WellPCB’s wire harnesses and cables are routed for EMI mitigation and thermal load tolerance with braided shield, coax and fiber optic lines in flame retardant XLETFE or PTFE jackets.
Each wire harness is engineered to meet ISO9001 quality controls and IPC/WHMA-A-620 Class 3 workmanship standards for installation across fuselage zones, landing gear bays and engine compartments.
Final assemblies are tested with 4-wire resistance measurement, dielectric withstand tests and 35–100 MΩ insulation resistance thresholds.
Harnesses are built with silver plated copper conductors, automatic strip and crimp processing and modular terminal layouts with validated pin insertion and mechanical retention.
Our Aerospace Wire Harness Capabilities
Our aerospace wire harness capabilities cover high-voltage power distribution, low-signal data transmission and environmental resilience across pressurized and unpressurized aircraft zones.
Each aerospace or aircraft wiring harness is engineered to match aircraft installation geometry, electrical load requirements and routing paths, including modular and flexible configurations. All assemblies are built with traceable materials, calibrated production equipment and closed-loop quality control systems to commercial aviation standards.
All harness manufacturing is ISO9001 and RoHS compliant.
We have a 0.5 inch routing clearance from hydraulic or fuel lines, shield terminations per IPC Standard, and serialize every wire bundle with laser marked ID per zone map and ICA spec.
Clamp spacing is 24 inches or less and each bundle is validated for twist angle, shrink placement and shield to ground continuity.
Avionics assemblies include coaxial cables with 50-ohm impedance, Ethernet Cat 5e/6 cabling with 100-ohm differential pairs and fiber optic cable assemblies with multimode 62.5/125 μm cores.
All signal harnesses have crimped and potted backshell connectors, EMI wrap with >60 dB attenuation and conformal sealed strain reliefs for fuselage to rack transition zones.
Engine bay and nacelle harnesses are made with silver- or nickel-plated copper wire, PTFE or XLETFE insulation rated to 260 °C, and ceramic thermal sleeving with overbraid for vibration resistance.
Conductor sizes range from 12 AWG for ignition signal to 22 AWG for thermocouple feedback. All terminals are crimped with +10 lb pull force minimum and encapsulated in high-temp shrink tubing with adhesive inner layers.
Generator harnesses have conductors rated to 600V, 115 to 120V AC and 28V DC branches isolated using flame-retardant conduit and dielectric barriers.
We use automatic laser strip and dual-stage crimp with CPK ≥ 1.33 for power terminals. Fault lines are segmented using inline fuses and bulkhead current limiters with MIL-style locking connectors.
We also make high-voltage harnesses for MEA platforms requiring power densities up to 1 MW.
Grounding cables have 0.003″ tinned copper braid with 360° terminations, contact resistance < 2 mΩ. Bonding jumpers have stainless ring terminals and are torque-tested to 20 in-lbs.
We provide fuselage-to-panel discharge links and equipment rack grounding harnesses with labeled clamps and moisture-resistant splices.
Wiring for lighting, galley systems, lavatory pumps, and flight deck controls has flexible stranded conductor layouts with UL-listed flame-retardant jackets and UL94 V-0 sleeving.
Wire gauges from 16 to 24 AWG are verified for bend radius ≥10× cable OD per installation requirement.
Assemblies with optical fiber and aluminum wire have Kevlar-reinforced cores, bonded shielding, and dual-path routing.
These are tested for light attenuation under bend (≤0.5 dB/m) and high-voltage dielectric resistance up to 1500VDC for MEA architectures.
We do single-unit and batch runs from 1 to 5,000 harnesses. In-house tooling includes automatic cutting (±0.2 mm accuracy), laser wire marking, high-speed terminal crimping (up to 8,000/hr) and digital test boards for netlist continuity verification.
All assemblies are inspected to IPC/WHMA-A-620 Class 3.
Why Choose WellPCB for Your Aerospace Wiring Harness?
WellPCB delivers aerospace wire harness solutions tailored to meet the electrical, mechanical, and documentation demands of commercial aviation programs.
Our process aligns with industry procurement cycles, supports rapid engineering validation, and integrates with client-specified vendor, connector, and material requirements to reduce rework and accelerate certification timelines.
ISO9001-Certified Harness Manufacturing
Each aerospace wire harness is produced under ISO9001-certified controls with full material and process traceability.
Precision Termination and EMI Shield Compliance
Flame-Retardant, High-Temperature Insulation Systems
Custom Routing Solutions for Complex Aerospace Applications
Fully Automated Assembly Process with Inline QA
Scalable Production with Documented Quality Data
Applications for Aerospace Wiring Harness Systems
Aerospace wire harness systems serve as the interconnect framework across aircraft structures, supporting power, signal, and data functions under variable load, thermal, and environmental conditions.
Whether installed in primary structures, rotating assemblies, or pressurized avionics bays, each harness must match platform-specific electrical requirements, physical constraints, and industry certification standards.
Commercial Airliner Wire Harness Systems
Regional Jet and Business Aviation Cabling Systems
Electric and Hybrid Aircraft Harness Integration
Urban Air Mobility (UAM) and eVTOL Aircraft Wiring
Design Requirements for Aerospace Wire Harness Production
Each aircraft wiring harness assembly must meet strict electrical, mechanical, and environmental criteria defined by both the aircraft system architecture and applicable industry standards. Material selection, termination precision, shielding integrity, and identification methods all contribute to the final harness performance and compliance.
Conductor Material and Wire Selection
Insulation, Jacket, and Shielding Specifications
Routing Geometry and Modular Layout
Connector, Pin, and Terminal Integrity
Identification, Traceability, and Documentation
Submit Your Design
Send us your design details (Drawing or Detailed Specifications).
Get a Fast Quote
Once your design and specs are received, a fast quote will be sent to you within 24 hours.
Confirm Order & Make Payment
When the quotation is approved, please send the PO or order confirmation, we will proceed with the production after receiving your payment.
Arrange Production & Inspection
Before production, our technical team will review all details of the drawing/specs again. If everything is OK, the order will start. We'll keep you updated throughout the manufacturing process. After the production is completed, the products will be 100% inspected.
Packaging & Delivery
When completed, your order will be carefully packed and shipped to you, with shipping documents and tracking information provided.
Aerospace Wire Harness Testing and Quality Controls
Aerospace and aircraft wiring harness testing validates each conductor, shield, and terminal against specification, with quantitative benchmarks for resistance, insulation integrity, and pull strength. Complete traceability ensures every cable assembly meets documented quality requirements.
Continuity and Resistance Testing
Insulation Resistance and Dielectric Withstand Testing
Mechanical Crimp and Pull Force Validation
Environmental and Stress Testing Protocols
Full Traceability and Documentation Controls
WellPCB is trusted by millions of
businesses and innovators.
Why Choose WellPCB as Your Wire Harness Manufacturer?
WellPCB stands out among USA wire harness manufacturers by delivering superior quality, advanced solutions, and unmatched reliability. With years of experience serving global markets, WellPCB has earned a reputation as one of the top wire harness manufacturers in the USA.
WellPCB specializes in custom wire harnesses for complex electronic and industrial applications. You can order these assemblies with $100 off using our special offer—delivering high-quality, tailor-made harnesses at competitive rates for your most demanding projects.
Hommer Zhao
Founder and Chief Editor – Hommer Zhao
Welcome! I’m Hommer Zhao, the founder and Chief Editor of WellPCB. With years of experience in the PCB industry, I’m committed to making sure our content is both accurate and helpful. We’re proud to serve a growing community of over 4,000 customers worldwide, and our goal is to provide you with the best resources and support. Your satisfaction is our top priority, and we’re here to help you every step of the way!
Jesse Holland
Technical Manager – Jesse Holland
Hi, I’m Jesse Holland, an Engineer and Technical Manager at WellPCB. With years of experience in PCB design and engineering, I’m here to ensure that every project we work on meets the highest technical standards. I lead our team, focusing on precision and innovation, collaborating closely with clients to provide tailored solutions and expert guidance. Whether you’re facing a complex design challenge or need advice on technical aspects, I’m here to ensure your project is a success from start to finish.
Nathan Jensen
Purchasing Manager – Nathan Jensen
Hi, I’m Nathan Jenson, the Purchasing Manager at WellPCB. I’m responsible for sourcing the best materials and components to ensure our products meet the highest quality standards. With my extensive experience in procurement, I work closely with suppliers to secure reliable and cost-effective solutions while maintaining strong relationships to support our operations. I aim to ensure every project runs smoothly by providing the resources needed to deliver on time and to your satisfaction.
Emma
Sales Manager – Emma
Hey, I am Emma, sales manager at WellPCB. I studied electronic science and technology at university and have served customers for PCB and PCB Assembly service for several years.

I enjoy communicating with customers and our technicians to solve problems, and customers always say, "It's great to have you onboard".

It is my pleasure and honour to be helpful. Contact me now, and you'll know.
Bella and Cassiel
Sales Representatives – Bella and Cassiel
We’re Bella and Cassiel, your dedicated sales representatives at WellPCB. With our extensive knowledge of the PCB industry, we’re here to provide exceptional service and support. We take the time to understand your unique needs and are always ready to offer tailored solutions and advice. Whether you need product recommendations, assistance with your orders, or simply have a question, we’re here to ensure your experience is smooth and seamless at every step.
Mandy and Wendy
Sales Representatives – Mandy and Wendy
We’re Mandy and Wendy, your friendly sales representatives at WellPCB. Passionate about helping our customers, we bring a wealth of experience in the PCB industry to provide you with the best solutions and service. We take pride in building strong relationships with our clients, understanding their specific needs, and offering personalised support to ensure their satisfaction. Whether you’re looking for advice, product information, or assistance with any part of your order, we’re here to make your experience as smooth and efficient as possible.
Our Team
Our skilled engineers and technicians bring expertise and precision to every PCB assembly project. Committed to quality, efficiency, and innovation, our team ensures every order meets the highest UL, IPC, ROHS & REACH standards, delivering reliable solutions tailored to your needs.
- Founder and Chief Editor – Hommer Zhao
- Technical Manager – Jesse Holland
- Purchasing Manager – Nathan Jensen
- Sales Manager – Emma
- Sales Representatives – Bella and Cassiel
- Sales Representatives – Mandy and Wendy
Aerospace Wire Harness Case Studies
PCB Assembly
Features:
- Resistant to extreme temperatures
- Fire and corrosion resistant
- Resistant to vibration and shock
- Lightweight design to reduce weight
PCB Assembly
Features:
Commonly used in sensors and instruments, thermal management, lighting systems, satellite systems, and entertainment & communication systems in aerospace
PCB Assembly
Main power source for aerospace equipments
Main applications:
- •Ground support equipment
- •Hybrid equipment
- •Emergency equipment
Client Feedback On Our Aerospace Wire Harness Products
As an R&D manager, I have had an outstanding experience working with WELL-PCB. For many years, our company has entrusted them with the production, assembly, and programming of the boards developed in our R&D unit, and they have consistently exceeded our expectations.
Hamid Reza Moshayedi
R&D Manager
Their work is very impressively perfect. Today, when they check our company PCB board after assemble. They found a fake short point which many engineers has never found in the past years. But that is just designed so. The PCB board quality is excellent. Their service is also excellent.
MikeZ
My friend introduced WellPCB to me, the first try, a little look forward to. I ordered a 47*72 10ps PCB, and I can’t wait to receive my PCB. So I used expedited service and received my PCB in three days. I tested and soldered the PCB, Quality is really good, silkscreen, plating also great.
Warren Cliton
Aerospace Wire Harness FAQs
What standards do your aerospace wiring harnesses follow?
Each electrical wiring harness is manufactured to ISO9001, IPC/WHMA-A-620 Class 3, and UL certification. Cable assemblies undergo insulation resistance, Hi-Pot, crimp, and continuity testing aligned with the latest industry standards for wire harnesses and cables used in aviation.
What validation testing is included in a standard harness build?
All aircraft wire harness builds include continuity verification, insulation resistance from 35 to 100 MΩ, dielectric withstand testing to 1,500 VDC, and crimp pull testing. We also inspect jacket integrity, shrink finish, conductor strip length, and connector pin retention.
Can you manufacture harnesses with fiber optic and coax integration?
Yes, we build hybrid cable assemblies with coaxial, fiber optic, and Ethernet conductors. These interconnect products are terminated with modular connectors and shielded to support signal integrity, EMI isolation, and routing through fuselage, avionics bays, and cabin systems.
Do you offer low-volume production or prototype harnesses?
Yes, we manufacture harnesses in quantities as low as one unit using the same high-quality materials, laser marking, and testing applied to production runs. Our process allows rapid turnaround for engineering validation builds or short-term flight test instrumentation.
Get Precision-Certified Aerospace Wire Harnesses Built to Your Specification
Get $100 Off Your First Order!
Partner with a manufacturer that delivers tested, traceable, and fully compliant wire harness assemblies for complex aircraft systems. Submit your specification and get a detailed quote, engineering review, and production timeline from our aerospace harness team.
