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Why Are Aircraft Wiring Harnesses So Expensive?

Why are aircraft wiring harnesses so expensive and what does this have to do with beer?


I always get asked, “Why are aircraft wiring harnesses so expensive?” A very good question that has multiple answers. I like to compare it to the booming craft beer industry. Breaking it down to the basics, there are 2 main expenses, material and labor.

When creating a “Craft Beer”, higher quality ingredients are used to create a unique flavor differing it from the “commercial” beers in the market. InterConnect Wiring builds wiring harnesses mainly for military aircraft such as the F-16 and UH-60. In order to meet the government’s requirements, InterConnect is required to purchase components with manufacturer’s certification. Each part has very specific tolerances and requirements that far exceed commercial parts. InterConnect is not allowed to stop by the local auto parts store and purchase a few wires and connectors in order to manufacture wiring harnesses.

Craft beer manufacturers employ specialists that engineer uniquely flavored beers one batch at a time. InterConnect Wiring employee specialists that work on wiring harnesses one harness at a time. Most wiring harnesses consist of 1 to over 500 wires. Wires get laid out individually by a single person. Each wire contains 2 terminations; therefore, every harness contains anywhere from 2 to over 1000 terminations. Each termination, whether crimp or solder, is individually completed by hand and then inspected by another person. Also each harness has to be taped, tied, and/or braided in order to maintain its shape. After the harness is complete, it goes through a testing process that tests every termination. A large quantity of hands touch each harness before it gets shipped to the customer.

InterConnect is proud that it is a small business in the United States employing many hard working Americans. Our F-16 and UH-60 harnesses are individually “handcrafted” in the USA with the finest “ingredients”. Contact InterConnect Wiring at 817-377- WIRE (9473) for more information about wiring harnesses.

Our License

We are the sole licensee of Lockheed Martin for F-16 electrical products. Through this agreement, we have access to Lockheed Martin’s F-16 engineering data, tooling and configuration control information. We also have a Technical Services agreement with Sikorsky for all of their aircraft. This agreement allows us to obtain their engineering data needed to rewire helicopters that Sikorsky manufactures.



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