CTAS offers a reconfigurable 8,000 square-foot avionics lab with the equipment, staff and space to produce a wide range of space system flight and ground cables, medical wire harnesses, military harness assemblies and electronic chassis. CTAS has extensive experience producing cable assemblies including soldering, crimping, multi-pinned connector terminations, extensive molding, potting, and testing.  The CTAS machine shop supports the machining of mold adapters for cable production to enhance production capabilities.

The avionics lab is configured to provide a working area to efficiently kit, assemble, and test cables and consists of independent workstations where certified electrical and quality personnel prepare and assemble cable assemblies and wire harnesses per customer approved planning. All components are cut, staged, and kitted to ensure accurate assembly and maximum production efficiencies. Depending on final specific test requirements, the cable assemblies and wire harnesses can be automatically tested for Hi-pot & Continuity checks, open shorts, and dielectric for all terminations.

cable assembly

AVIONICS LAB CAPABILITIES:

  • Cable Assemblies: HO (power), ML (data)
  • Connectors: General purpose, rectangular, high density, miniature, power, commercial, coax (TNC, SMA, HN and Tri-axial)
  • Terminations: Stripping (thermal and mechanical), soldering (NASA STD – 8739.4, NHB 5300 and MIL-STD 454), crimping, butt and parallel splices up to 4/0 AWG
  • Contacts & Terminals: From 26 AWG up to 4/0 AWG, flag terminals up to 4/0 AWG
  • Mechanical: -500 to +2,000 lbs for pull test requirements to certify/verify good crimps/splices (performed on test samples)
  • Testing: DC Hipot (manual to 3000 Volts Direct Current (VDC) and automatic to 1500VDC), Alternating Current (AC) dielectric (manual to 3000 VAC), continuity (manual and automatic). Automatic testing is performed to minimize time for end to end connection testing
  • Chemical Mix Crib: OSHA approved laboratory vent hoods, multiple ovens for elevated temperature chemical cures, and a de-aeration station for performing certified processes such as bonding, potting, etc.

PROJECT MANAGEMENT

The CTAS avionics lab manager utilizes over 25 years of experience in engineering, fabrication, testing
and installation of electronic systems to ensure contractual requirements are met and deliveries are on time and within budget.

Our Avionics Quality Manager has over 10 years of Aerospace Quality experience and is a NASA 8739.4 level B certified instructor, allowing for expedited training and certification of a skilled workforce necessary to assure timely delivery of a high volume of cables and rapid expansion of production capacity as needed. Our IPC-J-STD-001 certified technicians adhere to NASA work standards KSC-E-165, KSC-GP-864, KSC-STD-132 all required for NASA 8739.4 certifications along with other industry standard certifications.

CTAS maintains in-house expertise to manage procurement from CTAS approved suppliers for products and services ranging from commercial off the shelf to subcontracted custom services and special processes. These in-house procurement capabilities include personnel familiar with the technical requirements for acquisition of aerospace, defense and avionics hardware, subcontract management and supplier quality personnel.

QUALITY ASSURANCE

Our ISO 9001 and AS9100 RevD Quality Management Systems (QMS) ensure that certified processes are used to meet all design, test, and operational requirements. CTAS performs extensive quality review of customer requirements prior to job planning. Job planning provides sequential steps for fabrication and testing. Each fabrication step requires separate approval and testing performed includes documented results. Final inspection is performed and documented by a certified inspector prior to shipment of the product. A non-conformance reporting system is used to initiate, track, and successfully close any product non conformance reports.