At InterConnect Wiring, we are the world’s leading expert in aerospace wiring. Over the past 30+ years, we’ve manufactured hundreds of thousands of wiring harnesses, cable assemblies, fiberoptic assemblies, and panel harnesses for some of the most legendary aircraft flying today. Along the way, we’ve seen the good, the bad, and the “who thought that was a good idea?” when it comes to harness assembly design.
So, if you’re tasked with designing an aerospace wiring harness that’s destined to survive high-G maneuvers, extreme temperatures, and more than its fair share of maintenance crews, here are the first three of six useful tips to keep in mind.
1. Start with the Environment in Mind
Before you grab your CAD software and start routing wires like pasta noodles, ask yourself, “Where will this wiring harness or cable assembly live?”
- Is it running through a jet engine bay? (Heat will be your enemy.)
- Is it in the cockpit? (Shielding against EMI will matter.)
- Is it in a maintenance-friendly location, or will a mechanic have to do yoga just to reach it?
Designing for the environment upfront saves time, headaches, and, most importantly, budget later.
2. Choose Materials Wisely (They’re Not All Created Equal)
The right insulation and conductor material can make or break a wiring harness design. Aerospace wire isn’t just fancy copper with a jacket, rather, it’s engineered to resist heat, fluids, vibration, and even the occasional maintenance-tool “UH-OH’s”.
- PTFE or ETFE insulations are key for high-temp environments.
- Nickel-plated copper works well when corrosion is a concern.
Pick wrong, and your cable could age faster than a pilot flying nonstop red eyes.
3. Size Matters (For Wires, That Is)
Wire gauge is one of the most common pitfalls in design. Too small, and your cable will overheat or underperform. Too large, and congratulations—you’ve just unintentionally signed the avionics technicians up for a workout class. The sweet spot is finding the perfect balance between electrical load and manageable weight.
Rule of thumb: Always check ampacity charts and then double-check them.
Designing aerospace cable assemblies is equal parts science, engineering, and art. The best designs anticipate real-world conditions, balance performance with manufacturability, and make life easier for the people who build, install, and maintain them. Tune in next month for the NEXT THREE useful tips when designing an Aerospace Wiring Harness for Manufacturing.
