About Cabelio Systems
We built the wire harness manufacturer we wished existed when we were the customer.
Our story
Between us, we've spent over twenty years inside the aerospace industry, managing harness production on the Falcon program at SpaceX, running quality and operations at Blue Origin, and leading production teams at Bell Helicopter. We know what it's like to need fifty harnesses by Friday and not be able to find a single manufacturer who will pick up the phone.
The wire harness industry is a $103 billion global market, but it's structurally broken for the companies we care about most: the funded startups and emerging OEMs building the next generation of rockets, robots, and electric vehicles. Tier 1 suppliers require 10,000-unit minimums. Traditional job shops take weeks to return a quote. Offshore manufacturers introduce lead-time risk and ITAR complications. And nobody offers real visibility into order status or revision control.
We started Cabelio Systems to solve these problems from both sides. On the software side, we built Cabelio, a free, web-based harness design tool that generates instant quotes, manages revisions, and produces automated work instructions for our production floor. On the manufacturing side, we operate a semi-automated facility in Melbourne, FL that delivers IPC Class 3 quality from day one, with no minimum order.
The result is a manufacturer that works the way modern hardware teams expect: fast turnaround, transparent pricing, digital traceability, and engineering support from people who have actually built the systems you're wiring.
Leadership
Andrew Douglass
Co-Founder · Engineering Lead
Andrew spent a decade in aerospace and electrical engineering, including several years at SpaceX where he managed an engineering team of approximately twenty engineers and technicians. His experience spans harness design, systems integration, and production engineering across launch vehicles and spacecraft.
At Cabelio Systems, Andrew leads engineering, customer design support, and the development of the Cabelio platform. He's the person reviewing your DFM and making sure your harness is production-ready before it hits the floor.
Guy Kemp
Co-Founder · Operations & Quality Lead
Guy is a Navy veteran with ten years of hands-on aerospace manufacturing experience. He worked as a technician at Bell Helicopter, then moved to SpaceX as a quality inspector and technician manager, and most recently served as senior manager of production and operations at Blue Origin on the New Glenn program.
At Cabelio Systems, Guy runs production, quality assurance, supplier management, and workforce training. His background in IPC/WHMA-A-620 inspection and high-rate production environments means your harnesses are built right the first time.
Our facility
We operate out of a light-industrial facility in Melbourne, Florida, the heart of the Space Coast. Kennedy Space Center is thirty minutes away, and we're surrounded by L3Harris, Northrop Grumman, Collins Aerospace, Leonardo DRS, and a rapidly growing cluster of commercial space startups.
The production floor is organized into six sequential zones: receiving and storage, automated wire processing, crimping, harness assembly on custom formboards, quality testing, and shipping. Environmental controls include HVAC for temperature and humidity management, ESD-rated flooring, and dedicated climate-controlled storage for moisture-sensitive components.
Melbourne, FL 32901
Space Coast, Florida · 2-day ground shipping to the entire Eastern seaboard
Standards & certifications
We manufacture to the highest applicable workmanship standards from day one. These are not aspirational targets. IPC Class 3 is our production baseline.
IPC/WHMA-A-620 Rev. E
Workmanship standard for cable and wire harness assemblies. We manufacture to Class 3 (high-reliability) as our baseline.
IPC J-STD-001
Requirements for soldered electrical and electronic assemblies. Certification in progress to formally comply with this standard.
AS9100 Rev. D
Aerospace quality management system. Formal certification process underway with target completion within 12 to 18 months.
ITAR Registration
Required for defense-related manufacturing. Registration in process to support classified and export-controlled programs.