Military Wire Harnesses & Assemblies
Epec has extensive experience delivering complex wire harnesses and cable assemblies for military and aerospace electronics. With more than 70 years of industry experience, Epec is a trusted supplier to defense programs requiring highreliability interconnect solutions. Military cable assemblies are manufactured using a broad range of capabilities and a deep understanding of defensedriven design, documentation, and quality requirements.
Supporting prime defense contractors carries additional responsibility. Epec maintains strong quality systems, full traceability, and invests in the tools, equipment, and personnel needed to keep design, manufacturing, and inhouse testing resources.
At a Glance: Military Wire Harnesses
- Military wire harness assemblies are engineered to meet stringent aerospace and defense requirements for reliability, traceability, and environmental performance.
- Epec supports military programs with in-house design, fabrication, electrical testing, and over 30 years of environmental qualification experience.
- Assemblies are built and tested to recognized IPC, NASA, and MIL-STD requirements to ensure performance in extreme and missioncritical environments.
Military Wire Harness Capabilities
Epec provides endtoend support for military wire harness programs. Capabilities include cable and harness fabrication, full design support, and electrical testing such as continuity, capacitance, and highvoltage isolation testing. Assemblies can be manufactured directly from customersupplied drawings or developed from customer specifications, with Epec delivering a complete design and test package when required.
With more than 30 years of inhouse environmental testing experience, Epec supports qualification and screening aligned with military and aerospace expectations. This experience includes an understanding of military specifications, specialty component lead times, and the documentation required to deliver compliant, productionready assemblies.
Compliance and Industry Standards
Epec's military wire harness assemblies are manufactured and tested in compliance with established industry and defense standards. These standards support consistent workmanship, soldering quality, and process control across military and aerospace programs.
We Are in Full Compliance With:
- IPCA610 Rev. D
- IPC/WHMAA620 Rev. A
- JSTD001D Certified Soldering Instructor/Technicians
- NASA Soldering Specification 8739.3
- Production Unit Qualification Testing per MIL-STD810H
- EMI/RFI Testing per MIL-STD461E
Environmental Testing & Chamber Capabilities
Environmental testing is a critical component of delivering reliable militarygrade cable assemblies. Epec maintains inhouse environmental chambers and test equipment to perform qualification and screening tests aligned with military and aerospace specifications. These capabilities support validation of cable assemblies under temperature extremes, humidity exposure, corrosive conditions, and mechanical stress.
Temperature Testing
Per EIA36417:
Temperature testing evaluates the performance of cable assemblies across wide operating ranges. Testing is performed to confirm that materials, terminations, and assembly methods remain reliable at both elevated and reduced temperatures.
Thermal Shock
Per EIA36432:
Thermal shock testing subjects assemblies to rapid temperature changes to assess material compatibility and structural integrity. This testing identifies risks related to expansion, contraction, and longterm durability under cycling conditions.
Humidity
Per EIA36431:
Humidity testing exposes assemblies to controlled moisture levels to evaluate resistance to condensationrelated degradation. Performance under varying relative humidity conditions is validated to support field reliability.
Salt Spray
Per EIA36426:
Salt spray testing evaluates corrosion resistance for assemblies exposed to harsh environments. Controlled salt fog conditions help assess longterm performance where corrosion could impact electrical or mechanical integrity.
Shock & Vibration Testing
Military applications frequently require resistance to mechanical stress encountered during transport and operation. Shock and vibration testing supports validation of cable assembly performance under dynamic loading conditions consistent with defense environments.
Environmental Test Parameters
| Parameter | Value | Units |
|---|---|---|
| Temperature range | 38 to +260 | °C |
| Thermal shock range | 75 to +200 | °C |
| Humidity level | 20 to 98 | % RH |
| Salt spray concentration | 5 | % |
Connector Standards Supported
Epec supports militaryqualified connectors commonly used in defense and aerospace applications, including:
- MIL-DTL-24308
- MIL-DTL-28804
- MIL-DTL-83503
- MIL-DTL-38999
Frequently Asked Questions
Quick Links
- What applications are military wire harnesses used for
- Does Epec design wire harnesses or build from customer drawings
- What types of testing are performed on military cable assemblies
- Why is inhouse environmental testing important
- Which industry standards are followed for military harness assemblies
- Are militarygrade connectors supported
What applications are military wire harnesses used for
They are used in military and aerospace electronics that require high reliability, traceability, and environmental durability.
Does Epec design wire harnesses or build from customer drawings
Epec supports both custom designs based on customer specifications and builds from customer provided drawings.
What types of testing are performed on military cable assemblies
Testing includes electrical testing, environmental chamber testing, and military qualification and screening aligned with applicable standards.
Why is inhouse environmental testing important
Inhouse testing allows tighter process control, faster qualification, and direct alignment with military and aerospace requirements.
Which industry standards are followed for military harness assemblies
Assemblies comply with established IPC, NASA, and MIL-STD workmanship, soldering, and performance standards.
Are militarygrade connectors supported
Yes. Epec supports multiple MIL-DTL connector standards used in military and aerospace systems.
Reliable MilitaryGrade Cable Assemblies
Epec delivers military wire harness assemblies designed for performance in extreme environments and missioncritical applications. With decades of experience, in-house testing, and compliance with recognized military and aerospace standards, Epec supports defense programs with reliable, production ready cable assembly solutions.
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