Custom Cable Assemblies, Wire Harnesses & Manufacturing Services for Aerospace and UAS

Custom Interface Inc

Custom Interface is a world-class manufacturer and integrator of custom cable assemblies, wire harnesses and electro-mechanical assemblies for unmanned aerial vehicles (UAVs, drones, UAS, RPAS) and other aerospace systems.

With over 20 years of experience, we can provide innovative turnkey manufacturing solutions, systems integration, value-added engineering and prototype support for a wide range of defense, commercial and industrial UAS applications. Our custom wiring solutions have been selected by world-class clients including Boeing, Virgin Orbit and Insitu.

Custom turnkey manufacturing for UAS and aerospace

Custom UAS Cable Assemblies & Wire Harnesses

Mission-Critical Wire Harness Assemblies for Unmanned Aircraft

UAS Cable Assemblies & Wire HarnessesWith over one million flight hours without field failure, our wiring harnesses and cable assemblies for Group 2 and 3 unmanned aircrafts provide mission-critical, never-fail functionality under the most demanding of conditions.

We develop custom rugged wiring solutions for aerospace and can manufacture everything from interface panels and lighting, up to complete UAS command and control systems.

We excel at installing wire harnesses and associated electronics into composite UAS structures, and work continually with leading industry partners to improve harness routing and longevity. Our exacting and state-of-the-art processes, developed in conjunction with UAS OEMs, result in enhanced performance and reduced weight for unmanned aircraft and aerospace applications.

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Aerospace & UAS Manufacturing Services

Electro-mechanical and UAS Lead System Integration

We install our harnesses, as well as electronic componentry, into composite structures, such as Group 2 and Group 3 UAS airframes. As a leading systems integrator, we work closely with our customers to improve harness routing and product longevity, while simultaneously enhancing performance and reducing weight. We provide full functional testing of system assemblies to meet customer specifications. Learn more >

UAV Systems Assembly and Integration

Value-Added UAS Engineering Design Support

UAS Cable and Wire Harness IntegrationWe extensively review customer designs to ensure manufacturability and recommend cost-saving and quality-improving options. Our wide experience allows us to keep your design costs down and save weight in space-constrained UAS applications, as well as maximizing ease of connection for UAS field operators. Learn more >

Aircraft Prototyping Services

We support the development of UAS and aerospace prototypes and low initial production runs, helping you move from concept to working design in a matter of days. We can review drafts or schematics for manufacturability, build the prototypes and create a final document package for your product. Learn more >

Dedicated Project Support

Each customer is assigned a dedicated Client Services Specialist, who will work to ensure proper program flow and consistent, seamless service. Purchase orders, customer communications, configuration management and delivery co-ordination are all expertly managed to ensure high-quality results and on-time delivery. Learn more >

Testing & Quality Control

Custom Interface UAV Component Quality TestingWe target 100% quality on our customer products, and currently achieve over 99.4%. We are experienced with testing to NASA, Boeing, Airbus, FAA, ASME, and IPC 620 standards.

We work to a certified ISO9001:2015/AS9100D quality system, developing complete process control documentation packages and providing full traceability and transparency into each product build. Learn more >

Our testing capabilities include:

  • Microscopic visual inspection (40X optics)
  • Basic Continuity & Isolation testing
  • HiPot testing up to 1500VDC/1000VAC
  • Pull Force testing from 1 to 750 lbs
  • Servo Exciter testing
  • Resistance testing down to 50 milliohms
  • Automated testing up to 3,394 termination points
  • RF Cable VSWR and Insertion Loss testing up to 3000 MHz
  • Customer specified full system tests
  • Full comprehensive test reports for your records.

Supply Chain & Cost Management

Custom Interface specializes in Turnkey Manufacturing programs that help reduce cost and lead times over the entire life cycle of customer products. We leverage our robust supply chain management processes and longtime vendor partnerships to ensure that we maintain a thriving and cost-effective materials pipeline.

We can also work with you to customize stocking packages and raw materials safety stock programs to help mitigate lead time risks and ensure you can always meet demand. Learn more >

Certifications

We strive to exceed customer expectations, working to the highest standards and building superior quality into every product. Our certifications include:

  • ISO9001:2015 (ISO9001 compliant since 2000)
  • AS9100D (AS9100 compliant since 2009)
  • ITAR (International Traffic in Arms Regulations) Registered
  • Underwriters Laboratories Inc. / Canadian Standards Association Registered
  • IPC A 620
  • RoHS Compliant
  • AUVSI (Association for Unmanned Vehicle Systems International) Membership
  • SAM Verified Vendor: US Federal Contractor Registration System for Award Management
  • DoD Mentor Protégé Program: FLIR Systems Inc.

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