Cable Harness Assembly & Manufacturing

With expertise in cable design and on-site engineering support, IMS produces conceptualized cable drawings from your project

specifications. From simple cable design drawings to more complex engineering, our team of skilled engineers use a suite

of design software platforms including AutoCad and CATIA to produce original wire harness concepts specific to each unique application. We can build to your existing drawing specifications, or collaborate with your team through the development of new designs. Our engineering team has experience developing projects involving 3D modeling of sophisticated harness systems and interconnect solutions.

From concept to finished product, TT Electronics Integrated Manufacturing Services (IMS) provides end-to-end electronics solutions, including manufacturing and assembly of high quality cable harness and sub-systems for the Aerospace, Defence, Heavy Industrial and Rail markets.

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When you require on-site engineering services, IMS will send qualified engineering resources with IPC-A-620 expertise to your work site. Our on-site support offerings range from design consultation and prototype support, to

complete installation.

IMS has earned its reputation as a premier supplier of high performance, ruggedised cable harnessing solutions for harsh environments within the aerospace, defence, communications and industrial markets.

IMS also manufactures a variety of specialist backshells designed for EMP, EMC, TEMPEST and HIRF requirements.

Missile And Defensive Suites• Defensiveaidssuites• Testequipmentsolutions• Radarequipmentinterconnects

The drive to find stronger and lighter materials affect every element of modern aircraft design. By proactively working to design and produce advanced composites that meet your specifications, we help you stay ahead of the curve in an innovation driven market. IMS is a leader in the design of lighter, more compact interconnection systems featuring miniaturisation of connector products and lightweight wiring solutions. We understand that screening remains a high priority, and offer a full range of connector accessories as part of our portfolio to ensure that your design is never compromised.

Civil Aircraft • Landinggear• Flightguidancesystems• Enginemanagement

The civil aircraft market demands reliable manufacturing processes, and in this competitive market, lightweight, reliable, and cost-efficient design solutions are integral to success. IMS is at the forefront of rigid tube design and manufacturing, particularly for aerospace applications. IMS’ patented composite systems technology and certified manufacturing processes allow for greater flexibility of your product design, without loss of structural performance.

Naval Systems• Radarsystems• Submarinecommunications• Panelassemblies

At IMS, we understand the unique set of challenges faced by Naval applications in the design of interconnection systems. We offer screened cable and conduit systems approved for “above deck full threat EMP protection.” Our ability to manufacture interconnection panels ensures that environmental conditions are taken into account during the design process, before your product ever reaches the field.

Rotary Wing Aircraft• Militaryhelicopters• Searchandrescue• Commercialhelicopters

Vibration and salt spray are just two of the hazards facing military aircraft. IMS has developed a range of products that allow the termination of multiple screens in these types of harsh environments without causing degradation to interconnection systems.

Design and manufacture of complex cable harnesses form part of our core strengths. We are actively involved with all systems within helicopter operations including UOR activities system upgrades and role fits.

Military Fixed Wing Aircraft• Jetfighters• Propellertechnology• Reconnaissance• Missioncontrolsuites

The need for highly reliably electrical protection on military platforms is especially critical as environmental conditions such as lightning and warfare pose significant threats for interference with electrical systems in the air and on the ground.

IMS provides cost effective electrical interface systems designed to withstand the affects of EMC, EMI, EMP and HIRF along with the harshest of environmental conditions.

Military Land Based Vehicles• Trackedvehicle• ArmouredPersonnelCarriers(APC)• InfantryFightingVehicles• LightArmoredVehicles• UnmannedVehicles• Securityservices

IMS is committed to serving the armed forces through manufacturing partnerships with the largest aerospace, defense and homeland security companies in the world. As a proven industry leader with expertise in ruggedized electronics, we collaborate with customers to provide mission-critical solutions for the most challenging environments.

Application Experience

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Recent Cable Harness ProgramsIMS has achieved the highest industry quality standards for cable harness manufacturing including ISO9001, AS9100, and MIL-STD-790 certifications. Achieving and maintaining these high-level standards enable IMS to provide custom cable manufacturing to your meet your project specifications without compromising quality.

Should additional harness protection or Electromagnetic Compatibility (EMC) screening be required, we also offer additional specialist services.

Recent cable harness programs include:

• Communication and camera systems on MRAP vehicles

• Screened harnesses for missiles• Screened and super screened technologies• Landing gear harnesses on the Eurofighter

program• Cables for Boeing 787 Dreamliner• Cable systems for Joint Strike Fighter• Harness specialists for rotor wing aircraft • Harness specialists for military land vehicles

Standard or Bespoke BackshellsWe offer a full design and development support program in order to provide bespoke backshells and accessories to your individual needs. As such, each of the product ranges can be assembled to suit its particular mechanical and environmental requirements.

Backshells and accessories can also be purchased separately for retrofit as shown in the parts catalogue.

Post formed, lightweight composite tubes IMS is at the forefront of rigid tube design and advanced composites, particularly in aerospace applications. The drive to find stronger and lighter materials affect every element of modern aircraft design. Using our in-house expertise and patented manufah temperature variants, post forming for shaping, electrical shielding, and specified tolerances.

The typical carbon composite tubing characteristics we can cater for are:

Resistancetolerances

• Corrosiveresistant• Goodinherentfireperformancewithlowemissions

• Temperatureperformance(upto175degreeCelsius)

• Flameresistance• Fuel,oil,solventandchemicalresistant• Lowsmokeandtoxicity• EMCscreenedvariants

Sizespecifications

• Round,oval,semisquaretubing• Diametersof6mm–50mm• Wallthicknessof0.3–5.0mm

Othercapabilities

• Lasermarkingofcable• Panel/BoxWiring• Automatictestfacilities• Backshellsrange• IPC620Class3,highperformancesafetycriticalstandards

• 4AxisMilling• CAD/CAMrapiddesignandmanufacture• Multibranched,electricallyscreenedcableharnessesandcoduitsystems

• Overmouldedcables,RF/MicrowaveCables

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High Performance Machining

Our skilled engineering resources can provide component designs to your unique specifications. All CAD information is used to generate programs for the CNC machining capability. 3D models can be produced for prototype or small batch production and “fourth axis” can be used to reduce operations on the more complex components.

Most materials can be accommodated and plating services are provided by our approved supply chain, ensuring that our customers receive complete “end-to-end” solutions.

When your applications require comprehensive design, and a complete manufacturing solution that includes precision machining, IMS delivers.

We demonstrate our expertise in precision machining with high quality backshell accessories for cable harness applications. As technology and product requirements diversify, our ability to perform machining of solid or cast materials enables us to provide bespoke assemblies, many of which are used when building complete electronic systems.

About TT Electronics Integrated Manufacturing ServicesTT Electronics Integrated Manufacturing Services (IMS), a wholly owned subsidiary of TT Electronics plc, specialises in low volume, high mix electronics manufacturing services for the aerospace, defence, industrial, medical and rail industries. With manufacturing locations in North America, Europe and Asia, IMS provides high complexity electronics and electromechanical assemblies for regional and global manufacturing companies. With a reputation for quality, engineering, testing and integration, IMS provides every customer with personalised business solutions and global buying power.

In an effort to globalize our cable harness offering, the ABI (Smithfield, NC) and New Chapel Electronics (Fairford, UK) businesses have been integrated into IMS. These businesses bring a rich history of serving ruggedized aerospace and defense markets while expanding our regional cable harness offering in Europe and North America.

For more information, visit us at www.ttelectronics-ims.com GlobalSales@ttelectronics-ims.com

AmericasPerry, OH, USA Cary, NC, USA Tel: +1 440 352 8961

EuropeRogerstone, South Wales, UK Fairford, England, UK Timisoara, RO Tel: +44 (0)1633 892 345

AsiaSuzhou City, China Tel: +86 512 66611004