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Connected Aero is a newly established manufacturing division of Aerostar, Inc.  Bolstered by industry experts with over 25 years’ experience in providing interconnect solutions for commercial aerospace applications. Connected Aero specializes in producing complete integration kits for your aircraft retrofit programs that include wire harness & cable assemblies, electro-mechanical assemblies, and structural support parts.  With decades of experience in producing thousands of custom integration kits our skilled manufacturing team can take your design to delivery seamlessly while providing valuable insight on cost savings, manufacturability, and reliability. Our operation is structured for a high-mix, mid-to-low volume production that focuses on the highest quality product at a competitive price.  With first-hand knowledge of fleet installation complexities and downstream design changes, we understand the importance of meeting deadlines and getting it right the first time. Values We promote a team culture with an obsession for customer satisfaction and operational excellence while aligning ourselves with the industry to be responsive, flexible, and easy-to-do business with.  We value our customers’ needs and strive to exceed them on every order.

When experience and expertise matter... Get Connected!


Settled in a thriving aerospace sector of Mobile, Alabama – Connected Aero is co-located at Mobile Aeroplex alongside Airbus FAL (A321, A320, & A220), Airbus NA Engineering, VT Aerospace, and Continental Aerospace Technologies.  Mobile is a hotbed of aviation talent with an established industry network and local government charter to promote aerospace workforce development.

Integrated Kits And Wire Harnessing

With a dedicated wire harnessing facility, we can deliver build-to-print assemblies and custom integration kits that meet your installation needs.  Providing a one-stop-shop for all electrical and structural components.

  • Laser marked harness assemblies
    • Single end or multiple breakouts
    • No length or breakout limitations
    • Formboards, Jigs, Mockups
    • 100% Inspected and Tested
    • Built to IPC620 standards
  • Coaxial, composite, ethernet, data bus cabling
    • HDMI, USB, RF, Power
  • Electrical-Mech Assemblies
    • Integrated trays, control boxes, wired panels
  • Comprehensive fabrication
    • Equipment racks, doublers, brackets
  • Custom Kitting

Machining & Structure Assembly

Combining in-house final assembly and finishing capabilities along with utilizing strategic local partners, we can fulfill all your structural support needs efficiently and cost effectively.  Our Quality assures 100% compliance to Customer flow down and traceability requirements, which guarantees that only certified parts are produced by qualified manufacturers.

Precision Machining

Aerostar local partners:

  • 3 & 5 Axis Machining
  • CNC Abrasive Water-Jet
  • EDM (Electrical Discharge Machining)
  • Welding & Sheetmetal Fabrication
  • CMM Inspection
  • ISO9001:AS9100 Rev D Certified

Structure Assembly (In-House)

  • Build-to-Print
    • Simple to Medium complex parts
  • Racks, Trays, Panels, Doublers

Finishing (In-House)

  • Paint and Chemical Conversion
    • Masking and Prep
    • Prime and Top Coat

Value Added Services

Take advantage of our extensive experience in producing integration kits to help identify and fulfill your specific needs while streamlining your supply chain.  We offer valuable insights to manufacturability that can save you time and money in your installation design.

  • Manufacturability
    • Fabrication drawing review
      • Best practices & cost savings
  • Alternate parts evaluation
  • Laser Wire Marking
  • First Article Inspections (FAI)
  • 100% Traceability
  • Custom kitting, packaging, & labeling
  • MIL-SPEC, FAR, DFARS, PMA, FAA and OEM experience


At Connected Aero, Quality is a top priority that is embraced throughout the entire organization.  Our quality management system is ISO9001/AS9100D compliant with a commitment to continual improvement, safety, on-time delivery, and customer satisfaction.

Quality and product safety checks are built-in to every process with all assemblies 100% tested and inspected.  With a commitment to high standards, all wire harnesses and cable assemblies will meet or exceed IPC/WHA-A-620 and/or BAC5157 standards.

We proudly accept our responsibility to continuously improve our products, services and process efficiencies to ensure we contribute to our customers competitiveness and success.

AS9100D Certification scheduled Q2, 2023


Gordon Smart
Div. President/GM
Connected Aero


Wire & Cable Harness Capabilities

  • Direct or indirect (label/tag) wire and cable marking
  • Crimp or Solder sleeve shield terminations
  • Contact and connector terminations, both crimp and solder
  • Crimp or soldered Coax terminations
  • Installation of overbraid, sleeving (heat shrink and expandable), and shrink boots
  • Backshell Cable Clamp support installation or grounded shield terminations
  • Wire/cable routing, forming, tying (standard spot-tie or zip-tie)
  • Formed breakouts and bundle routing
  • Terminal Lug and ground contact installation
  • Wire splicing, crimp, solder, or solder sleeve
  • Continuity verification