Foyer Office space

Inspection Area Production Area

Wire Harness Capability

Engineering: Analysis & Design

Manufacturing: Build to Print

Test, Repair, Mod, & Overhaul

System Reliability Solutions

Airframes and Engine types: Boeing 757/767/747 MD11 Airbus A300/600 GE CF6-80 series PW4000 series PW2000 series

Manufacturers: Airbus BF Goodrich / Rohr Boeing General Electric Pratt & Whitney Unison

ATA Chapters & Components:

71 Powerplant / 73 Fuel & Control

Cowlings(inlet/core/trans) & T/Rs

EEC, IDG, Sensors, Fire Warning,

System Controls, EGT, Core Engine

APU Control Airframe & Engine

Types of Harnesses: Shielded & Unshielded Connectors Signal/Noise and Current Carrying Multi Wire Cables / Multi Cable Bundles Simple to Complex Multi Branched Group of Bundles Terminated

with Connectors or Terminals (depicted)

Daniels Cabinet Covering most Applications

Banding Tools Insertion / Extraction Tools Positioners

Crimping Tools: Hydraulic Pneumatic Manual

Star Aviation Inc. Designed Pull Tester

Confirms Crimp is within CMM Specifications Pull Test up to 1200 in lbs Capability from 32 gauge to

4/0 Wire (IDG 4/0 Wire Terminal Crimp Depicted)

Connector Vise with Custom Jaw Assortment Prevents Damage and Ensures Proper Torqueing

Total Crimp Quality AssuranceStar Aviation Inc. is the only Aerospace Company to utilize Micrographic Analysis. Cross Sectional Views are analyzed with the MacroZoom, in concert with ProprietaryAnalysis & Measuring Software, resulting inPrecision Data for Conformity Inspections.

Essential to Optimizing Harness Performance

Laselec MRO-200A UV Laser Wire & Cable Marking System

Contrast Achieved with the MRO 200-A Meets the Most Demanding Aeronautic Standards Allowing an Operator to read the Identification Mark without any Magnification.

Does not Damage Wire Jacket (unlike Hot Stamp Method).

Marks Tape Wrapped Wire, Polyimide/Kapton Wires (PTFE)ETFE and FEP like Airbus CF Teflon Wrapped ExtrudedWires: Teflon (PETF), Tefzel (ETFE, XLETFE).

Meets the Requirements of AS5649, ANSI, NAS, & NFPA.

Successfully passed all Tests for Legibility, Contrast, CrossSection, Fluid & Light Immersion, Thermal Ageing, SurfaceResistance, & Dielectric Withstands Required by Major Aircraft Manufacturers and OEMs.

Spectrum Technologies 210D Dual Beam Laser Wire Stripping System

High Quality and Damage-free, the Laser is Reflected.off the Conductor, Plating, or other Metallic Surface.

Increases Efficiency with Accuracy & Repeatability. Processes Multiple Wires or Cables Simultaneously. Works Across Majority of Insulation Types

Cobra 36 Carrier Wire Harness Braiding Machine

Braids Nickel Plated Copper or Stainless Steelor Textile/Yarn including Polyester and Nomex.

Provides in-house capability lowering cost anddecreasing lead-times.

Protection from Abrasion, Heat, and Fluids.

Known heat issue

Worked with OEM on problem which resulted in S.B. mod.

Mod only reduces temps by a fraction.

Affects all units in-service

All will end up like this or fail before it gets this bad.

Solder joints crystalize and fail.

Board substrate delaminates.

Heat profile after modification

Made to match OEM Parts and Schematic.

½ the price of OEM

Unlimited availability

Can supply under E.O. until a PMA can be obtained.

IRU & Emerg Light Batteries Outdated Testing Proceedure

CADEX 8000 Tester Results Screen Shot

Monitors Time, Voltage ,Current (Load), Temperature. Also doesInternal capacitance checks, and calculates Capacity.