Custom Wire Harness Assemblies for Automotive Test, Aerospace and Defense Programs
K-Tec Systems designs and builds custom wire harnesses in Ferndale, Michigan, for automotive test equipment, aerospace instrumentation, defense systems, UAS propulsion and medical devices. Assemblies are built to IPC/WHMA-A-620 and, where specified, U.S. MIL-SPEC. We handle design, 2D and 3D wiring diagrams, prototyping, production, electrical testing and documentation in-house, and ship a Certificate of Conformance with every order.
Request a QuoteA wire harness routes power and signal through a defined space and has to keep doing it under heat, vibration, EMI and repeated handling. We engineer each assembly to the operating environment, routing constraints, connector requirements and workmanship standard your program specifies, then build it to print with the documentation your incoming inspection and procurement teams need.
Wire Harness Manufacturing Capabilities
K-Tec Systems offers end-to-end wire harness services, from design consultation and prototyping through full-volume production and testing. We work directly with engineers and procurement teams to produce wire harnesses that meet your exact specifications. All wire harnesses are made in the USA at our Ferndale, Michigan, facility.
• Custom wire harness design and engineering
• 2D and 3D wiring diagram development
• Prototype and production runs, low and high volume
• Cable and connector assembly
• Sleeving, conduit, and tubing integration
• Electrical testing and continuity verification
• Repair and rework services
• Calibration services
• Certificate of Conformance with every order
• QR code product documentation (on-harness access to manuals)
Since 1989, K-Tec Systems has built reliable, custom wire harness assemblies using quality materials selected to withstand the operating conditions of your specific application — including extreme temperatures, high vibration, confined routing paths, and electromagnetic interference requirements.
How We Build a Wire Harness
- Design review. We work from your drawing, sample or schematic and produce a 2D or 3D wiring diagram for approval.
- Prototype. A first article is built and tested before production.
- Cut, strip, terminate and route. Conductors are cut to length, terminated with mil-spec or commercial connectors, and dressed with sleeving, conduit or heat-shrink as specified.
- Test. Every assembly is continuity-tested and electrically verified before it ships.
- Document and ship. Certificate of Conformance and QR-coded product documentation with every order.
Quality Standards: IPC/WHMA-A-620 and MIL-SPEC
Wire harness quality is not an afterthought at K-Tec Systems. Every assembly is manufactured and inspected to meet industry-recognized standards, with documentation provided for traceability and compliance.
| Standard/Credential | What It Means |
|---|---|
| IPC/WHMA-A-620 | The industry-recognized acceptability standard for cable and wire harness assemblies. K-Tec builds to IPC/WHMA-A-620 requirements, ensuring consistent workmanship across every assembly. |
| MIL-SPEC Compliance | Wire harnesses for defense and military applications are built to U.S. MIL-SPEC standards, meeting the material, construction, and performance requirements specified for military use. |
| Certificate of Conformance | Provided with every order to support your incoming inspection, qualification, and supply chain documentation requirements. |
| WBENC / WOSB Certified | K-Tec Systems is a certified woman-owned business recognized by the Women’s Business Enterprise National Council (WBENC). |
| Government Registered | Registered to do business with the U.S. Government. CAGE Code: 4W0S0. SBA Small Business designation. |
Industries We Serve
Industry |
Application |
|
Defense & Military |
K-Tec manufactures wire harnesses to U.S. MIL-SPEC standards for military ground vehicles, fire trucks, ambulances, command and control systems, and support equipment. Our defense wire harnesses are built for reliability under harsh field conditions and are backed by full documentation for procurement compliance. K-Tec is registered to do business with the U.S. Government (CAGE Code: 4W0S0). |
|
Aerospace |
Custom wire harness assemblies for aerospace platforms where weight, routing space, and signal integrity are critical. K-Tec works with engineers to specify materials, connectors, and construction methods appropriate for the altitude, vibration, and thermal environment of each application. |
|
Drone & Unmanned Systems (UAS/UAV) |
Wire harnesses for unmanned aerial systems require compact, lightweight construction without compromising reliability. K-Tec manufactures wire harnesses for UAS propulsion and engine systems, where precision wiring and secure terminations directly affect system performance and mission success. As the drone industry continues to expand across defense, commercial, and research sectors, K-Tec is positioned to support wire harness requirements for next-generation unmanned platforms. |
|
Automotive |
Wire harnesses for taillight assemblies, rear-view camera systems, EV and hybrid battery systems, onboard electronics, and automotive brake and engine test equipment. K-Tec has extensive experience with the complex wiring demands of electric vehicle powertrain and energy storage systems. Test-cell and dynamometer harnesses are built alongside the thermocouples they connect to, so sensor lead, connector and harness are matched before they reach your lab. |
|
Medical |
Wire harnesses for portable medical treatment devices and health monitoring equipment, manufactured to the high reliability and quality documentation standards required for medical applications. |
|
Industrial & Electronics |
Wire harnesses for electric panels, communications devices, and control systems, custom manufactured to meet the quality and reliability needs of the application. |
Materials & Components
K-Tec sources and works with a comprehensive range of wire harness components, selected based on the operating environment, regulatory requirements, and performance specifications of each application.
• Insulated conductors and multi-conductor cables
• Cords and custom cable assemblies
• Connectors (mil-spec and commercial)
• Terminals and splices
• Sleeving (braided, expandable, heat-shrink)
• Conduit and tubing (rigid and flexible)
• Strain relief and backshells
• Tie wraps, lacing, and bundling materials
• Labels and wire marking
• Shielded cables for EMI-sensitive applications
Wire Harness and Temperature Sensor from a Single Source
Many applications require both a wiring assembly and a temperature sensing solution. When those two components come from different suppliers, engineers face added complexity in procurement, lead time management, and ensuring compatibility between the sensor and the wiring it connects to.
K-Tec Systems manufactures custom thermocouples and RTDs in-house at the same Ferndale, Michigan, facility where we build our wire harnesses. That means one engineering team, one point of contact, and one qualified supplier accountable for both. Whether your application is in automotive engine testing, aerospace, defense, medical devices, or drone and unmanned systems, K-Tec can support the full wiring and sensing requirements from a single source.
Learn more about K-Tec’s custom thermocouple and RTD manufacturing.
Frequently Asked Questions
K-Tec manufactures wire harnesses for aerospace, defense and military, automotive, drone and unmanned systems, medical, and industrial/electronics applications. Our engineering team is experienced with the specific performance and documentation requirements of each sector.
Yes. K-Tec manufactures wire harnesses for military and defense applications to U.S. MIL-SPEC standards. We are registered to do business with the U.S. Government (CAGE Code: 4W0S0).
K-Tec builds wire harnesses to IPC/WHMA-A-620, the industry-recognized acceptability standard for cable and wire harness assemblies. A Certificate of Conformance is provided with every order.
Yes. K-Tec manufactures wire harnesses for drone and unmanned aerial system (UAS/UAV) propulsion and engine systems. Our wire harness assemblies for unmanned platforms are built for compact, lightweight construction with the reliability that mission-critical applications demand.
K-Tec supports both. We work with customers from early-stage prototype through full production runs, with engineering support available throughout the process.
Lead time varies by complexity, materials, and volume. Contact our engineering team with your specifications for a lead time estimate.
Yes. K-Tec Systems manufactures custom wire harnesses and custom thermocouples and RTDs, giving engineers and procurement teams a single source for both the wiring assembly and the temperature sensing solution it connects to.
Contact our engineering team to discuss your application requirements and request a quote. Call 248-414-4100, or reach us at contact@k-tecsystems.com.
IPC/WHMA-A-620 is the industry acceptability standard for cable and wire harness assemblies. It defines workmanship criteria for terminations, crimps, splices, routing and labeling. K-Tec Systems builds to IPC/WHMA-A-620 requirements and can build to customer-specified classes on request.
Yes. Every K-Tec Systems wire harness is designed and built at our facility in Ferndale, Michigan.
Talk to a K-Tec Engineer About Your Wire Harness Needs
Ready to discuss your wire harness requirements? Our engineering team will get back to you asap. Complete the form below or call us directly at (248) 414-4100.