HARNESS
AS9100D · UL · CSA · IPC/WHMA-A-620Registered since 2009 · ISO-certified facility · Phoenix, AZ

The nervous systems
your hardware depends on.

Custom cable assemblies and wire harnesses manufactured to MIL-spec, IPC-620, and AS9100D for aerospace, medical, and industrial automation programs. Proto to production volume under one roof.

Request Your Custom QuoteDownload Our Capabilities PDF
MIL-DTL-38999BRAIDED SHIELD · 96% COVERAGEAL/MYLAR FOIL WRAPDRAIN WIREJACKETPVC/PTFE6-COND. BUNDLE

OPERATING TEMP

−65°C to +200°C

VOLTAGE RATING

Up to 10 kV RMS

CONDUCTOR RANGE

26 AWG — 2/0

SHIELD COVERAGE

≥ 96% Optical

SCROLL TO REVIEW CAPABILITIES
CERTIFIED

SECTION 01 · CAPABILITY OVERVIEW

The certifications are on the wall.
The data is in the wire.

Every assembly leaves our floor with documented test records, traceability to raw material lot numbers, and a first-article inspection package your quality team can hand directly to the FAA, FDA, or Tier 1 auditor.

AS9100D

Aerospace Quality Mgmt

UL Listed

Underwriters Laboratories

CSA Certified

Canadian Standards Assoc.

IPC/WHMA-A-620

Wire Harness Workmanship

MIL-DTL-38999

Circular Connector Spec

RoHS Compliant

Hazardous Substance Directive

8–12 wk

Standard Lead Time

Proto to production

3–5 wk

Expedited Lead Time

Pre-qualified designs

26 AWG

Minimum Gauge

Signal-grade wire

2/0 AWG

Maximum Gauge

Heavy power cable

500+

Connector Families

MIL, commercial, hybrid

10 kV

Max Voltage Rating

High-potential tested

CONNECTOR FAMILIES · PARTIAL LIST

MIL-DTL-38999 Series III/IVMIL-DTL-5015D-Sub (9 – 78 pin)M12 / M8 Field BusLEMO B / C / SAmphenol PT SeriesTE DEUTSCH DT/DTMSouriau 8STAHypertronics HyperGripCustom Overmolded
Download Our Capabilities PDF· 2.4 MB · Updated Feb 2026

SECTION 02 · PERFORMANCE DATA

Three verticals.
Documented outcomes.

These aren't marketing claims — they're quality records pulled from closed NCR reports, first-article packages, and production dashboards. Numbers that survive a supplier audit.

Aerospace

Defense Avionics OEM · Tier 1 Prime

Flight-critical harness rework eliminated in 3 production cycles

MIL-DTL-38999 Series III, 47-position · AS9100D FAI package · Hipot @ 1,500 V DC

Pass-First-Time Rate99.4%
Field Failure Rate0.003%
Rework Hours Saved1,240hrs/yr
Medical

Surgical Robotics Platform · Class III Device

34% reduction in assembly cycle time on a Class III surgical system

Silicone-jacketed, biocompatible · Autoclave-rated to 134°C · UL/CSA dual-listed

Cycle Time Reduction34%
IPC-620 Pass Rate100%
Lot Traceability100%
Industrial Automation

High-Speed Packaging Line · 24/7 Operation

Zero unplanned downtime events across 18-month production run

M12 D-coded, IP67 rated · PVC drag-chain rated · 10M flex-cycle qualified

Unplanned Downtime Events0
Assembly Hours Saved28%
Continuity Test Pass99.9%
See Full Case Studies & Test Reports

SECTION 03 · BUILD PROCESS

From schematic to
certified shipment.

Five gates. Every one documented. No assembly leaves without a complete data package your quality team can file, audit, and defend.

STEP01

Design Review & DFM

1–3 days

Your engineer speaks directly with ours. We audit your schematic, BOM, and drawing package for design-for-manufacturability issues — catching impedance mismatches, incorrect crimp barrel selections, and strain-relief oversights before a single conductor is cut.

DFM ReportRevised BOMApproved Drawing Set
STEP02

Rapid Prototyping

5–10 days

First physical units built to print. Prototype assemblies receive the same test regimen as production parts: continuity, insulation resistance, and dimensional inspection. You receive a marked-up redline drawing with any field findings.

3–5 Proto UnitsContinuity RecordsRedline Drawing
STEP03

First Article Inspection (FAI)

3–5 days

Full AS9100D-compliant FAI package: dimensional report per the drawing, material certs, pull-force test records, and photographic evidence of every crimp cross-section. The package ships with the first-article units.

AS9100D FAI PackagePull-Force RecordsCrimp Cross-Sections
STEP04

Volume Production

Per schedule

Production runs from 50 to 50,000 units. Work instructions are revision-controlled, operators are IPC-620 certified, and every assembly is built to the same approved first-article. Real-time WIP visibility available via our portal.

IPC-620 Certified OperatorsRev-Controlled Work InstructionsWIP Portal Access
STEP05

Hipot & Continuity Testing

100% of units

Every assembly is hipot-tested at 1.5× rated voltage and continuity-verified against a golden reference board. Test data is logged per serial number. No unit ships without a passing test record attached to its traveler.

Per-Unit Hipot RecordsContinuity Test LogCertificate of Conformance
INDUSTRY

SECTION 04 · INDUSTRY VERTICALS

Built for environments
where failure is not an option.

Aircraft cockpit instrumentation panel with complex wiring harnesses visible
99.4% first-pass yield

Aerospace & Defense

  • MIL-DTL-38999 Series III/IV
  • AS9100D FAI Packages
  • DO-160G Environmental
  • ITAR-Compliant Handling
Medical imaging equipment in a clinical environment showing precision cable routing
100% IPC-620 compliance

Medical Devices

  • Biocompatible Jacketing
  • UL/CSA Dual-Listed
  • Autoclave-Rated to 134°C
  • Class II/III Device Exp.
Industrial robotic arm on an automated manufacturing line with cable management systems
0 downtime events / 18 mo

Industrial Automation

  • M12 / M8 Fieldbus
  • IP67/IP69K Overmolding
  • Drag-Chain Flex-Rated
  • 10M Flex-Cycle Qualified

START YOUR PROJECT

500 custom assemblies.
Your delivery window. Our problem to solve.

Submit your drawing package, BOM, and target volume. We return a firm quote with lead time commitment within one business day — no sales call required.

Request Your Custom QuoteDownload Our Capabilities PDF