At InterConnect Wiring, we are the world’s leading experts in aerospace wiring. Over the past 32+ years, we’ve manufactured hundreds of thousands of cable assemblies, wiring harnesses, and electrical assemblies 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 electrical wiring harness design.
Below find Part 2 of 2 of Six Useful Tips When Designing Aerospace Wiring Harnesses
(From the Folks Who Build Them Every Day). You may want to first reread Part 1 of 2, which reminds you that the environment, materials, and size matter.
Six Useful Tips When Designing a Cable Assembly for Manufacturing – InterConnect Wiring
Now, as promised, here are tips 4, 5 and 6!
4. Don’t Forget Bend Radius
Cable assemblies aren’t meant to do gymnastics. Every wire has a minimum bend radius, and ignoring it is asking for broken conductors, insulation cracks, or signal loss. A cable routed like a pretzel may look creative on paper, but in real life, it’s a maintenance nightmare.
5. Label Early, Label Often
If there’s one universal truth in aerospace wiring, it’s this: mechanics love labels. The more clearly each reference designator, breakout, and wiring harness is labeled, the faster troubleshooting becomes. Skimping here may save pennies upfront but will cost big dollars later. Think of labels as the “name tags” at a party—they keep everyone from guessing who’s who.
6. Work With Your Manufacturer (We’re on Your Team!)
The best designs come from collaboration. Don’t treat your manufacturer like the last stop in the process—bring them in early. At InterConnect Wiring, we’ve helped engineers refine designs so they’re easier (and cheaper) to produce while still meeting every spec. Remember: a great cable assembly on paper isn’t always a great cable assembly in production.
In summary, 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.
At InterConnect Wiring, we’ve learned that a little foresight in cable design goes a long way in keeping aircraft mission ready. So next time you’re sketching out a new design, keep these tips in mind—and if you want an experienced partner to double-check your masterpiece, you know where to find us: Contact Us – InterConnect Wiring.
