Aerospace Cable Assemblies & Wiring Harnesses
Cabling solutions for flight, defence, and commercial aerospace applications.
Cable Assemblies Built for Demanding Flight Environments
In aerospace and defence applications, wiring harnesses serve as the core communication network between flight control, navigation, power distribution, and telemetry systems. Operating conditions in these sectors require consistent performance under sustained physical stress.
Flair Electronics provides aerospace cable assemblies & wiring harnesses to withstand severe operational conditions, including:
- Thermal Extremes: Materials specified for continuous ambient operating temperatures ranging from -55°C to over +175°C.
- Vibration & Mechanical Wear: Laced looms and overmoulded strain relief options engineered to handle high-vibration areas near engines, airframes, and unmanned aerial vehicles (UAVs).
- Electromagnetic Interference (EMI): Braided shielding configurations (tin, silver-plated copper, or stainless steel) designed to maintain signal integrity in dense electronics environments.
- Weight & Space Efficiency: Compact, thin-wall wire builds designed to minimize weight and fit tight bay envelopes.
Our Aerospace Cabling Capabilities
- Avionics & Systems Harnesses: Multi-branch wiring looms for flight management systems, cockpits, radar equipment, and power distribution units.
- MIL-SPEC Connector Integration: Precision termination and assembly incorporating circular connectors such as MIL-DTL-38999, MIL-DTL-26482, MIL-DTL-5015, and MIL-DTL-83723.
- Lightweight Cabling for UAVs: Compact, micro-miniature assemblies engineered specifically for payload bays where weight savings are critical.
- Commercial Off-The-Shelf (COTS) Solutions: Cost-effective COTS alternatives using commercial-grade connectors compatible with military specs—suitable for ground support equipment, test rigs, and non-flight monitoring.
- RF & Coaxial Assemblies: Low-loss radio frequency cabling for satellite communication links, GPS modules, and onboard radar.
UK Engineering & European Scale
Flair Electronics offers a flexible supply model through a combination of UK and European production facilities:
- UK Facility (Hitchin): Engineering Support & Rapid Prototyping
- Rapid turnarounds for New Product Introduction (NPI) and early-stage development.
- Direct access to engineering support for schematic review and component selection.
- Dedicated capability for low-volume, high-mix production runs.
- European Facilities: Volume Manufacturing
- Scaled manufacturing for higher-volume, ongoing supply contracts.
- Structured inventory management and batch delivery options.
- Direct transfer of builds from UK prototyping lines to European production.
- UK Facility (Hitchin): Engineering Support & Rapid Prototyping
Frequently Asked Questions
Q: Can Flair Electronics assist with component sourcing for specific circular connectors?
- A: Yes. We work with established supply chains to source accredited military-standard connectors, as well as equivalent commercial parts for COTS projects where budget or lead time dictates.
Q: Do you offer build-to-print manufacturing from customer drawings?
- A: Yes. We manufacture directly from customer schematics, CAD files, or physical samples, providing full drawing checks prior to manufacture.
Q: What documentation accompanies completed orders?
- A: Every shipment can include Certificates of Conformity (CoC), First Article Inspection Reports (FAIRs), and full electrical test certification depending on project requirements.
Discuss Your Aerospace Cabling Project
STEP 1: SUBMIT YOUR RFQ
STEP 2: GET YOUR QUOTE
STEP 3: PLACE YOUR ORDER
We hold ISO9001:2015 for the assembly of printed circuit boards and cable assemblies. We follow the IPC 620 wire harness and cable assembly guidelines using our own certified trainer. To learn more about our certifications please click here.