Aerospace Cable Assembly Quality: AS9100 & Workmanship Standards

Aerospace cable assemblies live or die by workmanship, not paperwork. AS9100 gives the framework, but the shop floor decides quality. Every termination must follow a documented work instruction with a calibrated tool, a defined crimp height, and a cross-section photo on file. Harnesses for flight-critical loops require 100% continuity and hi-pot testing at 500 VDC minimum, with results tied to the serial number. Conductor dress radius must not fall below 10× the cable OD, and strain relief is mandatory at every connector backshell. Process traceability — who, when, which tool, which lot of contacts — is not optional. If any of these is missing from the quote, you are not buying an aerospace assembly.