Precision Wiring Solutions for Every Application
At Defender Interconnect Systems, we specialize in custom wiring harnesses tailored for prototyping and low-volume production. Whether you're developing a new product or need a short run of specialized assemblies, we deliver fast, flexible, and precise solutions to meet your unique requirements. Our hands-on approach ensures high-quality craftsmanship, quick turnaround times, and the adaptability needed to support innovation at every stage.
OUR CAPABILITIES
CUSTOM WIRE HARNESS ASSEMBLY
We specialize in building high-quality custom wire harnesses tailored to your unique specifications and applications. Whether it's a prototype or a low-volume production run, we ensure precision, durability, and clean integration every time.
BUILD TO PRINT WIRE HARNESS ASSEMBLY
Have your own design? We provide expert build-to-print wire harness services, ensuring each assembly meets your exact drawings and standards with consistent quality and attention to detail.
CUSTOM WIRE HARNESS DESIGN
From concept to completion, we work with you to develop custom wire harnesses optimized for your application. Our design process focuses on performance, reliability, and ease of installation.
CUSTOM FRONT PANEL AND ENCLOSURE DESIGN
CUSTOM PELICAN CASE DESIGN
HARNESS TESTING
We design and fabricate custom front panels, gauge and accessory panels and enclosures that combine functionality with a clean, professional look. Whether for control systems or display interfaces, we tailor every detail to your technical and aesthetic requirements.
Protect your equipment with custom-designed Pelican cases featuring foam inserts, wiring access, panel mounts, and integrated electronics. Built for durability, mobility, and convenience in demanding environments.
Every harness we build or repair can be thoroughly tested for continuity, shorts, and proper pinout using industry-standard equipment. Our testing ensures your harness is reliable and ready to perform right out of the box.
CONNECTOR POTTING
For added durability and environmental protection, we offer connector potting services using high-quality compounds. This process seals connectors against moisture, vibration, and contamination—ideal for rugged or outdoor applications.
CABLE AND WIRE HARNESS REPAIR
Extend the life of your equipment with our expert cable harness repair services. We diagnose and restore damaged cables by replacing connectors, repairing broken wires, and re-terminating ends—delivering reliable performance without the cost of full replacement.
DESIGN PROTOTYPING
Defender Interconnect Systems offers fast, high-quality design prototyping to help clients test and refine wiring harness solutions early in development. Our functional prototypes support quicker validation, reduce risk, and ensure a smoother path to full production.
INDUSTRIES
COMMERCIAL
INDUSTRIAL
AGRICULTURE
PERFORMANCE
AUTOMOTIVE
QUALITY
Built for Reliability, Backed by Craftsmanship
Quality is at the core of everything we do at Defender Interconnect Systems. Each wiring harness we produce is built and tested to IPC/WHMA-A-620 standards by our technicians. We strive for clean, consistent craftsmanship and long-term durability. We use only high-grade materials and industry-proven techniques to meet or exceed customer expectations. Whether it's a one-off prototype or a small production run, our attention to detail and commitment to excellence ensure every connection is made to last.
Cable Assembly QA Inspection Checklist
Incoming Material Inspection
· [ ] Materials match BOM and PO (connectors, wire, heat shrink, etc.)
· [ ] Certificate of Conformance (C of C) received and reviewed
· [ ] Shelf-life verified (where applicable)
· [ ] Material traceability logged (if applicable)
In-Process Inspection
· [ ] Wire cut and strip lengths within tolerance
· [ ] Crimp quality verified (crimp height, pull test performed on sample)
· [ ] Solder joints inspected (IPC compliant)
· [ ] Correct wire routing and connector pinout verified
· [ ] Shielding/grounding inspected and secured
· [ ] Proper bundling, lacing, or sleeving applied
Final Inspection and Testing
· [ ] Visual inspection complete – no damage, FOD, or workmanship issues
· [ ] Connector and backshell torque verified
· [ ] Labels and markings present and legible
· [ ] Continuity test passed
· [ ] Insulation resistance / HiPot test (if applicable)
· [ ] Tug/pull test completed
· [ ] Dimensions verified against print
Documentation and Sign-Off
· [ ] Traveler/work order completed and signed
· [ ] Test results recorded and filed
· [ ] Nonconformances documented (if any)
· [ ] Inspector sign-off complete
