Avionics Wiring Harnesses

Partnering with Tier-1 aerospace contractors, Frigate engineers custom Avionics Wiring Harnesses that deliver flawless signal integrity and power distribution in high-vibration, high-altitude environments. Our AS9100-ready manufacturing infrastructure ensures every custom assembly complies with rigid military and commercial aerospace standards.

Applicable Standards

AS9100 Rev D, IPC/WHMA-A-620 Class 3, MIL-DTL-22520

Conductor Materials

High-strength copper alloy, silver-plated copper, nickel-plated copper

Insulation Materials

XL-ETFE (Tefzel), PTFE, Polyimide (Kapton)

Wire Gauge Range

12 AWG to 30 AWG (custom coaxial and twinaxial integration available)

Shielding Efficiency

Minimum 95% optical coverage braided shielding (optimized for EMI/RFI)

Order Type

Quantity Range

Lead Time*

First Article Inspection (FAI) / Sample

1 – 5 Units

4 – 6 Weeks

Low-Rate Initial Production (LRIP)

6 – 50 Units

8 – 10 Weeks

Full-Rate Production (FRP)

51 – 250 Units

12 – 14 Weeks

High-Volume Blanket Orders

251+ Units

Scheduled Monthly Releases

*Timelines are indicative and depend on component availability, specific tooling requirements, and testing protocols. Exact schedules are finalized upon final engineering review.

Product Description

Frigate’s aerospace-grade wiring harnesses serve as the central nervous system for critical flight decks, radar systems, and electronic warfare suites. Engineered with advanced EMI shielding and lightweight, high-performance insulation, these assemblies offer unmatched reliability under extreme thermal and mechanical stress.

Operating Temperature

-65 ° C to +200 ° C (continuous operational exposure)

Voltage Rating

Up to 1000 V AC / 1500 V DC at high-altitude flight profiles

Insulation Resistance

≥ 5000 M Ω at 500 V DC (tested per EIA-364-21)

Dielectric Withstanding Voltage

No breakdown or flashover at 1500 V AC at sea level

Connector Integration

MIL-DTL-38999 Series I, II & III, MIL-DTL-83513 (Micro-D), ARINC 600

Protective Sleeving

Nomex braiding, Viton heat-shrink tubing, PEEK monofilament

Outgassing Compliance

Meets NASA SP-R-0022A (TML < 1%, CVCM < 0.1%)

Testing Protocols

100% continuity, high-pot testing, automated cirris harness inspection

Environmental Sealing

IP67 / IP68 at connector interfaces via overmolding or fluorosilicone grommets

Vibration Resistance

Random vibration testing per MIL-STD-810G, Method 514.6

Technical Advantages

Utilizing advanced braided shielding and Mu-metal wrapping, Frigate harnesses isolate sensitive data lines from electromagnetic interference to ensure zero packet loss in dense electronic environments. Furthermore, engineered with cross-linked ETFE (Tefzel) insulation and ruggedized backshells, these assemblies maintain exceptional mechanical integrity and fluid resistance across an extreme operational temperature range of -65° C to +200° C.

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Industry Applications

Commercial Airliners (Flight Control Systems)

Delivering high-fidelity signal pathways between flight control computers and primary actuators, guaranteeing redundant, fail-safe fly-by-wire operations.

Military UAVs & Defense Systems

Ruggedized, low-weight wire assemblies built to withstand high-G maneuvers, payload deployments, and extreme tactical environments.

Satellite & Space Payload Integration

Ultra-low outgassing harnesses designed for deep-space vacuum environments, powering sensitive orbital telemetry, transponders, and imaging arrays.

Business Jets & General Aviation

Tailored cabin management and glass cockpit avionics integration, optimizing space and weight while maintaining maximum payload performance.

Rotary-Wing & Marine Aircraft

Heavy-duty assemblies with advanced sealing against high-frequency vibration, salt-fog corrosion, and hydraulic fluid ingress.

Radar & Electronic Warfare (EW) Suites

High-bandwidth, phase-matched coaxial harness assemblies supporting radar, missile warning systems, and active electronic countermeasures.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

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Having Doubts? Our FAQ

Does Frigate manufacture wiring harnesses according to IPC Class 3 standards?

Yes. All Frigate avionics wiring harnesses are manufactured, inspected, and verified strictly to IPC/WHMA-A-620 Class 3 standards, ensuring maximum performance and zero downtime under critical operating conditions.

How does Frigate manage engineering design changes (ECOs) during production?

We maintain a strict configuration management and revision control system. When an Engineering Change Order (ECO) is triggered, our team immediately updates the digital wire harness schematics, automated testing programs, and production routing files to ensure seamless integration without disrupting delivery schedules.

How does Frigate handle the traceability and quality control documentation for aerospace parts?

Every shipment comes with a comprehensive manufacturing quality data package. This includes Certificates of Conformance (CoC), full material traceability back to raw wire and connector lots, and automated continuity test logs.

What are Frigate’s capabilities regarding First Article Inspections (FAI)?

We provide comprehensive First Article Inspection documentation in accordance with AS9102 guidelines. This includes complete dimensional verification, functional testing results, and manufacturing process sign-offs prior to production ramp-up.

How do you optimize wiring harnesses for weight-sensitive aerospace applications?

Our engineering team collaborates with your designers to optimize routing, utilize lightweight insulation materials like cross-linked ETFE, and integrate PEEK or Nomex sleeving to minimize weight without compromising shielding or durability.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Components Built for Critical Performance

Engineered Products for Critical Applications

Avionics Wiring Harnesses

Order Type

Quantity Range

Lead Time*

Product Description

Operating Temperature

Voltage Rating

Insulation Resistance

Dielectric Withstanding Voltage

Connector Integration

Protective Sleeving

Outgassing Compliance

Testing Protocols

Environmental Sealing

Vibration Resistance

Technical Advantages

Let's Get Started

Industry Applications

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

Avionics Wiring Harnesses

Get Latest Price

Avionics Wiring Harnesses

Get Latest Price