Industry Platform
Aerospace wire harnesses and cable assemblies for avionics, EWIS power distribution, sensors, in-flight entertainment and UAVs — M22759 airframe wire, D38999 connectors and MIL-STD-1553 databus, built to AS9100 quality requirements and IPC/WHMA-A-620 Class 3 workmanship.
Application Context
An aircraft wire harness is not commercial cable cut to length. It flies through wide temperature swings, low pressure at altitude, constant vibration, fluid exposure and lightning-strike currents — all while carrying flight-critical power and data where a single open or short can ground an aircraft. That is why aerospace harnesses are built from qualified materials: M22759 PTFE/ETFE airframe wire rated to 260°C, MIL-DTL-27500 shielded cable for EMI and lightning protection, and D38999 circular connectors with environmental backshells — assembled to mil-spec construction and workmanship standards from the first cut.
Across an airframe the wiring changes job at every zone: dual-redundant MIL-STD-1553 and ARINC 429 databus running avionics, EWIS power distribution feeding bus bars and generators, sensor and actuator harnesses on flight controls and engines, cabin and in-flight entertainment distribution, and ultra-light payload wiring on UAVs. We build each as a custom, weight-optimized assembly using high-temperature cable, shielded constructions and coaxial cable where signal integrity matters — all 100% electrically tested before they leave the floor.
Applications
Aircraft harnesses and cable assemblies for every zone of an airframe and payload.
Signal-integrity harnesses for navigation, communication, radar and flight-management systems. We build MIL-STD-1553 dual-redundant databus, ARINC 429 point-to-point links and CAN backbones with controlled-impedance shielded pairs that keep telemetry clean inside an electrically noisy airframe.
Primary and secondary electrical wiring interconnection system (EWIS) harnesses for power distribution, bus bars and generator feeders. High-strand copper conductors, separated routing and lightning-protective shielding are built to SAE AS50881 aerospace wiring practice.
Flight-control, fuel, hydraulic and engine-monitoring harnesses linking sensors, servos and actuators. High-temperature M22759 wire and MIL-DTL-38999 backshell-banded terminations survive the heat, vibration and fluid exposure of zone and engine-nacelle installations.
Cabin management, seat power, lighting and IFE distribution harnesses. Lightweight, weight-optimized constructions with shielded data lines route through seat tracks and overhead bins while meeting cabin smoke, flammability and weight-budget requirements.
Lightweight, flexible harnesses for unmanned aerial vehicles, autonomous aircraft and payload bays. Fine-strand copper-alloy conductors and miniature D38999 / micro-circular connectors cut weight where every gram costs endurance.
Rugged cable assemblies for aircraft ground power units, maintenance test sets and airport service vehicles. Heavy-duty MIL-DTL-5015 connectors and abrasion-resistant jackets handle repeated mate cycles on the ramp.
Engineering Challenges
Material selection and process controls for continuous +260°C zone and nacelle service, vibration fatigue and thermal cycling across the airframe.
Shielded MIL-DTL-27500 construction, banded backshell terminations and separated routing engineered for EMI rejection and lightning-strike protection on safety-critical electronics.
High-strand copper-alloy conductors, thin-wall M22759 insulation and miniature D38999 connectors to trim airframe weight without sacrificing reliability.
100% continuity and dielectric-withstand testing plus altitude, temperature-cycling, vibration and signal-integrity verification, documented to aerospace requirements.
Technical Capabilities
M22759 / MIL-DTL-27500 construction with D38999 connectors and MIL-STD-1553 / ARINC 429 databus, validated for high-altitude, high-temperature airborne service.
Manufacturing Process
Quality & Testing
Every aircraft harness gets 100% continuity and dielectric-withstand testing, with altitude, temperature-cycling, vibration and signal-integrity verification where the application calls for it — all documented for lot-level traceability before it ships.
Why WHP
Aerospace cable assemblies that pass inspection and fly reliably for the life of the airframe.
Harnesses manufactured to AS9100 quality requirements, IPC/WHMA-A-620 Class 3 workmanship and SAE AS50881 aerospace wiring practice, under our held ISO 9001 quality system.
M22759 PTFE/ETFE airframe wire, MIL-DTL-27500 shielded cable and lightweight high-strand copper/copper-alloy qualified for high-altitude and high-temperature performance.
Weight-optimized assemblies using high strand-count wire and miniature D38999 connectors to minimize aircraft weight penalties without sacrificing reliability.
100% continuity and dielectric-withstand testing on every harness, plus altitude, temperature-cycling, vibration and signal-integrity verification to aerospace requirements.
Our aircraft harnesses are built to the aerospace and workmanship standards that integrators and quality teams require. We hold ISO 9001 and IPC/WHMA-A-620; AS9100 and SAE AS50881 are applied as build-to requirements.
FAQ
OEM Program Entry
Share drawings, BOM, photos, or early-stage requirements. Our aerospace engineering team will review manufacturability, connector and material selection, EMI/lightning protection, testing needs, and production requirements before manufacturing starts.
Related Capabilities
Custom cable assembly and harness services that pair with aircraft programs.