Wire harness design & assemblies
Harness design and documentation in-house; build-to-print and build-to-design harness and cable assemblies produced by qualified manufacturing partners.
02 — Electrical Systems & Wire Harnesses
Connecting mission-critical systems.
Engineering coordination, sourcing and production support for wire harnesses, cable assemblies, electrical assemblies and interconnect systems.
Electrical systems built around the mission.
Wire harnesses and interconnects carry power, signal and data through every platform. LIGHTNX designs harnesses in Zuken E3.series and CR-8000 with a maintained ECAD component library, models mechanical integration in PTC Creo, and treats each assembly as a system of decisions — contacts, inserts, shells, backshells, shielding, conductors, marking and routing hardware — each with its own sourcing, quality and documentation implications.
Film
Built for the mission.
From a single crimped contact to the platform it powers: harness engineering, build by qualified manufacturing partners, inspection and test, then installation across air, land and maritime systems.
Scope
Connector & interconnect sourcing
Circular and rectangular connectors, contacts, backshells, accessories and tooling-dependent components.
Harness documentation review
ECAD drawings, wiring lists, formboard layouts and marking requirements checked for completeness before release.
Build & test flowdown
Termination, inspection and electrical test requirements flowed to the builder and confirmed in the delivery record.
Design environment
Engineered in industry-standard tools.
Designs, libraries and drawings are produced in-house, so what a supplier builds and tests traces directly back to the engineering definition.
Schematic & harness design
Zuken E3.series and CR-8000 for schematics, wiring lists, harness layouts and formboard drawings.
ECAD component library
Connector, contact, wire and accessory parts modeled with pinouts and attributes so every design is buildable and sourceable.
Mechanical integration
PTC Creo for 3D routing, bracket and enclosure design, bend radii and clearance checks.
Test & validation definition
Continuity, insulation-resistance and functional test requirements defined for the builder and verified in the delivery record.
Interactive engineering view
Every decision, made visible.
Scroll to separate a generic circular interconnect along its assembly axis — contacts, insert, shell, coupling ring, backshell, boot, shield, conductors and routing hardware. Each part is a sourcing, quality and documentation decision.
ContactsPlating, size, termination
InsertArrangement & keying
Shell & flangeMaterial, finish, mounting
Coupling ringMating & retention
BackshellStrain relief & shield termination
Heat-shrink bootEnvironmental transition
Braided shieldEMI performance
ConductorsGauge, insulation, spec
ID sleeveMarking & traceability
P-clipRouting & retention
- Contacts: Plating, size, termination
- Insert: Arrangement & keying
- Shell & flange: Material, finish, mounting
- Coupling ring: Mating & retention
- Backshell: Strain relief & shield termination
- Heat-shrink boot: Environmental transition
- Braided shield: EMI performance
- Conductors: Gauge, insulation, spec
- ID sleeve: Marking & traceability
- P-clip: Routing & retention
Platform applications
Interconnect across domains.
The same engineering discipline applies wherever power, signal and data have to survive vibration, temperature, moisture and tight routing.
Air systems
Avionics and equipment-bay harnesses, weight-conscious routing, configuration control.
MarketsLand systems
Vehicle electrical architecture, power distribution, ruggedized connectors and enclosures.
MarketsMaritime systems
Shipboard cabling, sealed assemblies and corrosion-resistant interconnect.
MarketsC4ISR & electronics
Interconnect for communications, sensors and electronic enclosures.
Markets
Method
- 01
Define
Configuration, materials and acceptance tests confirmed against the drawing package.
- 02
Source
Interconnect components and wire sourced with documentation suited to the requirement.
- 03
Build
Assembly performed by a qualified harness manufacturer to the flowed-down requirements.
- 04
Verify
Inspection and test records collected and reviewed before shipment.
What to bring
- Harness drawing / wiring list
- Connector & wire specifications
- Marking & labeling requirements
- Test & inspection criteria
Start with a non-sensitive overview. Controlled technical data is exchanged only through the authenticated Program Workspace.
What you receive
- Component sourcing plan
- Builder requirement flowdown
- Inspection & test records
- Traceable delivery package
Discuss a requirement
Bring us the requirement.
Tell us what the program needs, when it is needed and which documentation matters. We will review it and define the path to delivery.