Mission-Critical Interconnects
For Aerospace & Defense
Engineered for Zero-Failure performance in extreme environments. From LEO satellites to tactical ground vehicles, Cablum delivers SWaP-optimized, ITAR-compliant wire harness solutions.
Engineering for the Unforgiving Vacuum of Space
In the aerospace sector, "reliability" isn't just a buzzword—it is the difference between mission success and catastrophic failure. A single compromised crimp or a micrometer of insulation damage can ground a fleet or disable a satellite.
Cablum Cable provides custom wire harness solutions engineered to meet these demands. We specialize in high-density, lightweight interconnects. We understand the critical importance of SWaP (Size, Weight, and Power) optimization. Our engineers design harnesses that deliver maximum signal integrity in the smallest possible footprint, using materials that withstand radiation and outgassing.
The Anatomy of Mission-Critical Design
We don't just build cables; we engineer structural components for your electronic architecture.
Advanced Materials & SWaP Optimization
An aerospace harness is a fight against gravity. Every gram counts.
We utilize Cross-linked ETFE (Tefzel), PTFE, and Kapton insulations that offer superior dielectric strength with minimal wall thickness. For shielding, we use lightweight composite shields and metalized fibers to provide high EMI attenuation at a fraction of the weight.
Space Ready: We strictly control Total Mass Loss (TML) and CVCM according to ASTM E595 standards, ensuring zero outgassing.
Precision Manufacturing & IPC Class 3
Our assembly technicians are certified to IPC/WHMA-A-620 Class 3—the highest standard for high-performance electronic products.
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Laser Wire Marking: Non-damaging, permanent identification for every circuit, essential for maintenance.
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Machine Crimping: Automated crimping with pull-force validation to ensure gas-tight connections.
Rigorous Validation & The "Paper Trail"
In defense, documentation is as important as the hardware itself. We provide complete First Article Inspection (FAI) reports per AS9102.
Before shipping, every harness undergoes automated testing for continuity, shorts, and insulation resistance (IR/Hipot). We maintain full lot traceability for every component ensuring rapid response capability.
View Quality Certifications
Case Study: LEO Satellite Constellation
Challenge: A satellite client needed to reduce harness weight by 20% while maintaining shielding effectiveness against harsh space radiation.
Solution: We engineered a custom harness using Micro-D connectors and metalized fiber shielding, reducing weight by 24% and passing all ASTM E595 outgassing tests.
Supporting Missions Across All Domains
UAVs & Drones
Ultra-lightweight harnesses for payload and flight control systems.
Space Systems
NASA/ESA compliant materials with low outgassing properties.
Ground Vehicles
Rugged, overmolded assemblies resistant to mud, oil, and shock.
Radar & Comms
High-frequency RF coax assemblies and phase-matched cables.
Technical Capabilities At-a-Glance
| Certifications | AS9100D, ISO 9001:2015, UL Listed, IPC/WHMA-A-620 Class 3 |
|---|---|
| Regulatory | ITAR Registered, RoHS, REACH, DFARS Compliant Materials |
| Connector Systems | MIL-DTL-38999, Micro-D (M83513), Nano-D, ARINC 600, SMA/SMP/TNC |
| Wire Types | M22759 (Tefzel), M16878, Coaxial (RG/LMR), Databus (1553B), Thermocouple |
| Testing | Cirris Automated Testing (Continuity, IR, Dielectric Breakdown), Pull Force |
Frequently Asked Questions
Common queries regarding our aerospace manufacturing services.
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Ready to Launch?
Don't let interconnects be the weak link in your mission. Partner with Cablum for engineering-led harness solutions that deliver when it matters most.
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