Precision in every strand. Purpose in every connection
In an era where signal clarity and reliable power can define mission success, and where failure is never an option, At TT Electronics, we don’t just manufacture cable assemblies, we engineer certainty.
Our value lies not only in built-to-print excellence, built in build-to-trust partnerships. ISO, AS9100-accredited, IPC-certified, and battle tested across air, land, and sea, we bring agility, responsiveness, and engineering depth to every programme we support.
The Importance of Cable Harness Assembly Standards for Harsh Environments and Military Programmes
Cable Harness assembly standards are essential for military programmes for several reasons:
Reliability: Standardised cable harnesses minimize the risk of electrical failures, ensuring uninterrupted system performance in harsh environments.
Safety: Compliance with industry standards guarantees the safe operation of critical systems, protecting both personnel and equipment.
Interoperability: Standardised cable harness assemblies facilitate seamless integration with other components and systems, reducing the complexity of system design and maintenance.
Regulatory Compliance: Adhering to established standards helps organizations meet regulatory requirements, avoiding costly fines and reputational damage.
At TT Electronics, our ruggedised cable harness assemblies are built to the IPC/WHMA-A-620 Class 3 standard, the industry’s leading workmanship standard for high-performance electronic interconnections. Additionally, we maintain the following accreditations to uphold quality and regulatory compliance:
Industry Accreditations
We operate under globally recognised certifications that validate our commitment to precision and reliability:
ISO9001 – International standard for quality management systems
AS9100 – Aerospace industry quality standard ensuring safety and reliability
Nadcap – Accreditation for aerospace and defence manufacturing excellence
IPC/WHMA-A-620 – The industry benchmark for cable and wire harness assemblies
These certifications ensure our cable harness assemblies meet or exceed the stringent requirements of aerospace, defence, and high-reliability industrial applications.
MIL Connector Specifications
Our cable harness assemblies utilise a wide range of rugged MIL-specification connectors to ensure compatibility with various applications. Below is a list of commonly used connectors:
Connector Standard | Description |
|---|---|
MIL-C-D38999 Series 1, 2 & 3 | High-performance circular connectors for aerospace and military applications |
MIL-C-26482 | Bayonet and threaded coupling circular connectors |
MIL-C-5015 | Rugged connectors for power and signal applications |
MIL-C-83723 | Environmental-resistant circular connectors |
MIL-C-26500 | Aerospace-grade connectors with high durability |
MIL-C-81511 | High-density military connectors |
BS9522 | British standard connectors for military and industrial applications |
MIL Wire Specifications
We use premium wire options designed to withstand extreme environments. Below are the wire specifications we frequently use:
Wire Standard | Description |
|---|---|
MIL-C-27500A | Multi-conductor shielded and unshielded cables |
MIL-W-5086/X | Insulated aircraft wire |
MIL-W-8777 | High-temperature airframe wire |
MIL-W-22759/X | High-performance aerospace wire |
MIL-W-25038/X | Fire-resistant, high-voltage aircraft wire |
MIL-W-81044/X | Low-smoke, flame-resistant wire |
MIL-W-81381/X | Polyimide insulated wire for extreme conditions |
Backshell/Adaptor Specifications
Backshells and adaptors enhance the durability and performance of cable harness assemblies. Below is a list of commonly used backshells/adaptors:
Backshell/Adaptor | Application |
|---|---|
NCB1 | Standard environmental backshell |
NCB3 | EMI/RFI shielded backshell |
NCB4 | High-temperature rated backshell |
NCB8 | Vibration-resistant backshell |
NCB9 | Quick-disconnect backshell |
NCB13 | Sealed backshell for harsh environments |
NCB15 | Military-grade backshell |
Frequently Asked Questions
To assist engineers, procurement teams, and customers, we’ve compiled answers to common questions about our cable harness assembly specifications.
Q: What industries require cable harnesses built to IPC/WHMA-A-620 Class 3?
A: Industries such as aerospace, defence, medical, and industrial automation require Class 3 assemblies for high-reliability applications.
Q: How do I determine the right wire specification for my cable harness?
A: The choice depends on factors such as voltage rating, temperature resistance, and environmental conditions. Our technical team can ensure the right cable design for the application and requirements.
Q: Are custom connector configurations available?
A: Yes, we offer customised solutions to meet unique application needs. Contact us to discuss your requirements.
Conclusion
High-quality cable harnesses are crucial for ensuring the reliability, safety, and performance of complex electronic systems in the aerospace and defence industries. At TT Electronics, we're dedicated to providing cable harness assemblies that meet the most stringent industry standards. Our technical expertise, combined with our commitment to quality and regulatory compliance, makes us the ideal partner for your project needs.
Discuss your cable harness project with our team today and discover how TT Electronics' expertise can support your success.