Cable & Wire Harnesses

Polytronix fabricates custom cables and wire harnesses specially designed by our engineering team according to your needs. We manufacture at any length with any size terminal, supported by automated machinery configured for both small and large production runs, from high-mix work to large production runs. Automated wire stripping, automated wire cutting, automated coax stripping, automated coax cutting, and auto-crimping cells deliver repeatable, controlled-cycle terminations across short-run prototypes and large production runs.

Our shop supports military specification (MIL-spec) and commercial requirements with IPC/WHMA-A-620 certified workmanship at Class 2 and Class 3, complemented by hi-pot, continuity, and 100% functional testing. Our technicians hold IPC/WHMA-A-620 and 620S, IPC J-STD-001, and IPC-A-610 credentials, plus ANSI J-STD-001 certified soldering and NASA-STD-8739.3 soldered electrical connections certification for high-reliability and space-grade work. As a full-capability manufacturing partner to the Department of Defense (DoD) and commercial aerospace, we engineer and integrate cable assemblies for flight-critical, mission-critical, and ground-based applications.

Cable and wire types span round military and commercial cable, ribbon cable, Cat 5/6 networking cable, microminature circular and small-gauge high-flex assemblies (smaller than 28 AWG), Nano (M32139) and MicroD (M83513) connector assemblies built from components, microminature coaxial, Quadrax, Twinax, Triax, semi-rigid and flexible RF coaxial, low-loss coaxial, Silicon Dioxide (SiO2) high-temperature coaxial, and specialty coaxial including WL Gore and Heliax. Harness jackets include polyurethane, PVC, EPDM, fluoroelastomer, polyolefin, expando, and Low-Smoke Zero-Halogen (LSZH) materials, with polychloroprene and polyurethane molding processes available for over-molded transitions.

Termination methods include automated crimping, hand and machine soldering with Low Temperature Solder (SN63) and High Temperature Solder (SN96, application dependent), over-molding, potting and backshell assembly, and shield termination by solder, banding, or constant-force spring methods. Connector and component tinning, de-golding procedures, magnification workstations at 6x and greater, and segregated silver-plate-wire processing support high-reliability and space-grade workflows. Class 100 and Class 1000 clean-room facilities, Foreign Object Elimination (FOE) plans, shelf-life control on parts, ESD-capable workstations when required, and wire storage at less than 50% relative humidity protect assembly quality from receipt through ship.