Aerospace Wire Harness Standards: NASA & ESA Compliance Requirements

Aerospace wire harnesses are subject to some of the most stringent requirements in the electronics industry. From the vacuum of space to launch vibrations and radiation exposure, wiring systems must meet exacting standards to ensure safety and reliability. This article outlines the critical NASA and ESA standards relevant to aerospace wire harnesses.

Key Agencies and Standards

NASA-STD-8739.4: NASA’s Workmanship Standard for Crimping, Interconnecting Cables, Harnesses, and Wiring.

ECSS-Q-ST-70-26C: European Cooperation for Space Standardization (ESA), focused on wire wrapping and harness requirements.

IPC/WHMA-A-620: Industry consensus standard, widely used as a base for aerospace-specific addendums.

Materials and Component Requirements

Wire Insulation: ETFE, PTFE, and Kapton are commonly used for their heat resistance and dielectric strength.

Anschlüsse: Space-rated, MIL-spec connectors with locking mechanisms.

Shielding: EMI/RFI protection via braided or foil shielding.

Assembly and Fabrication Guidelines

Crimping vs Soldering: NASA and ESA favor crimped connections for reliability.

Routing and Lacing: Must avoid sharp bends and use lacing cords instead of zip ties.

Strain Relief: Critical for mitigating launch and vibration stresses.

Testing Protocols

Continuity and Insulation Resistance: 100% verification.

HiPot Testing: Ensures insulation can withstand voltage spikes.

Outgassing Tests: For all non-metallic materials.

Vibration and Shock Testing: Simulates launch environments.

Documentation and Traceability

Full documentation required for each harness:

Bill of Materials

Routing schematics

Workmanship records

Material certifications

Parts must be traceable to lot and batch.

Certification and Audit

In-house or third-party ESA/NASA-certified auditors

Cleanroom requirements for final assembly

Conclusion

NASA and ESA standards ensure aerospace harnesses meet the highest benchmarks for reliability and safety. Compliance is complex but essential for participation in high-stakes aerospace programs.