What Is Included in Raineon's Custom Turnkey Wire Harness Fabrication Service?
Raineon Custom Turnkey Wire Harness Fabrication
Raineon provides comprehensive turnkey wire harness fabrication services, managing the entire process from design review through final delivery. Our service eliminates the need for multiple vendors and ensures consistent quality throughout the supply chain.
Service Scope
- Design Review and Optimization: Our engineering team reviews your harness drawings and specifications, identifying opportunities for cost reduction, weight optimization, and manufacturability improvements. We provide DFM (Design for Manufacturability) feedback at no additional charge.
- Material Sourcing: We source all wires, connectors, backshells, tubing, and hardware from qualified suppliers. Our established supply chain relationships ensure material availability and competitive pricing.
- Wire Cutting and Stripping: Precision automated wire cutting and stripping to exact lengths with ±0.5mm tolerance. Laser stripping available for delicate conductors.
- Crimp Termination: All crimp terminations performed per IPC/WHMA-A-620 and NASA-STD-8739.4 standards using calibrated tooling. Every crimp is pull-tested to verify mechanical integrity.
- Assembly and Routing: Harness assembly on precision form boards that replicate the installation geometry. Complex multi-branch harnesses are assembled by experienced technicians.
Quality Assurance
- 100% continuity testing on every circuit
- Insulation resistance testing (megger) at 500VDC
- Hi-pot (dielectric withstand) testing per specification
- Visual inspection per IPC/WHMA-A-620 Class 3
- Dimensional verification against form board drawings
Documentation Package
Every harness ships with a complete documentation package including test reports, material certifications, as-built drawings, and a certificate of conformance. Full traceability from raw material to finished harness.
Lead Times
Standard lead time is 4-6 weeks for prototype harnesses and 6-8 weeks for production quantities. Expedited service available for urgent requirements.
Connector Compatibility
Raineon turnkey harness services support a wide range of military and commercial connector families, including Micro-D (J30J series), D38999 (MIL-DTL-38999 Series III), and other high-reliability interconnects. Our engineering team provides connector selection guidance based on your application requirements.
Wire Specifications
We work with all standard aerospace wire types including Spec 55 (Raychem), M22759, and M27500. Wire selection is based on temperature requirements, chemical exposure, and weight constraints specific to your application.
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