Description
Assemble, terminate, bundle, label, and install electrical wire harnesses and cable assemblies for aircraft, spacecraft, and missiles. Use wiring diagrams and harness boards to route conductors, fit connectors and backshells, apply shielding and protective coverings, and inspect and test to aerospace standards.
- • Assemble prefabricated wires, connectors, contacts, and backshells into wire harness subassemblies.
- • Lay out and route conductors on harness boards or fixtures per wiring diagrams and index points.
- • Cut and strip wire and cable to master lengths using cutters and automated strip machines.
- • Crimp contacts and terminals with calibrated tools; verify crimp height and pull strength.
- • Solder splices, terminations, and shield drains in accordance with approved procedures.
- • Bundle, lace, and apply heat-shrink or expandable sleeving to harness branches.
- • Install connectors, backshells, strain reliefs, grommets, and protective boots.
- • Fit and terminate EMI/RFI shields and grounds; apply braids and shielding tapes as specified.
- • Mark wires and assemblies with labels, sleeves, or laser markings per identification requirements.
- • Verify harness lengths, breakout locations, pinouts, and keying using measuring tools and gauges.
- • Inspect workmanship and components for damage, FOD, and compliance with standards.
- • Perform continuity, insulation resistance, and hipot tests using multimeters or automated testers.
- • Clean contacts, connectors, and harnesses with approved cleaners; apply sealants or potting compounds when required.
- • Set up and operate wire cutting, stripping, crimping, and kitting equipment per work instructions.
- • Fabricate jumpers, pigtails, adapters, and test cables using shop equipment.
- • Prepare travelers and record build data, serials, and test results in production documentation.
- • Route and install harnesses in aircraft, test rigs, or benches using clamps, brackets, and fasteners.
- • Coordinate with structure and avionics teams to integrate harnesses into assemblies without interference.
- • Rework or replace wires, contacts, or connectors to correct defects or engineering changes.
- • Dress, trim, and restrain harnesses to ensure proper fit, clearance, and bend radii.
- • Torque connector hardware and backshells to specification and verify keying orientation.
- • Apply ESD controls, FOD prevention, and tool accountability during all operations.
- • Capture and segregate wire scrap, solder dross, solvents, and packaging for recycling or proper disposal.
- • Support prototype and engineering development builds and incorporate redlines into the harness board.
- • Read and interpret wiring diagrams, schematics, connector tables, and work instructions to determine sequences.
- • Package, tag, and protect finished harnesses for storage or shipment.
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This site includes information from O*NET by the U.S. Department of Labor, Employment and Training Administration (USDOL/ETA), used under the CC BY 4.0 license. Career Clutch has modified some of this information for student readability. USDOL/ETA has not approved, endorsed, or tested these modifications. O*NET® is a trademark of USDOL/ETA.
Last reviewed: Jan 2026
