{"id":4753,"date":"2025-06-27T11:45:10","date_gmt":"2025-06-27T11:45:10","guid":{"rendered":"https:\/\/avenirtechno.com\/?page_id=4753"},"modified":"2025-07-08T10:49:31","modified_gmt":"2025-07-08T10:49:31","slug":"harness-fabrication","status":"publish","type":"page","link":"https:\/\/avenirtechno.com\/index.php\/harness-fabrication\/","title":{"rendered":"Harness Fabrication"},"content":{"rendered":"\t\t
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We specialize in the precision fabrication of aerospace-grade wire and cable harnesses<\/strong>, built to meet the rigorous demands of space, avionics, and defense applications. Every harness is engineered with mission-critical reliability<\/strong>, ensuring optimal electrical performance, mechanical durability, and environmental resistance.<\/p>

Our in-house capabilities cover the full lifecycle\u2014from design support and prototyping<\/strong> to high-mix, low-volume production<\/strong>, all under strict adherence to standards such as IPC\/WHMA-A-620, NASA-STD-8739.4, and ECSS-Q-ST-70-26<\/strong>. We use only space-rated materials<\/strong>, including PTFE, ETFE, Kapton\u00ae, and shielded or twisted-pair configurations for EMI-sensitive systems.<\/p>

Each harness is tested for continuity, insulation resistance, and signal integrity<\/strong>, with full traceability and documentation provided for every assembly.<\/p>

Our Harness Fabrication Capabilities Include:<\/strong><\/p>

  • Custom wire and cable harnesses for flight, ground, and test systems<\/p><\/li>

  • Shielded, twisted, coaxial, and high-speed data cable integration<\/p><\/li>

  • Precision routing, lacing, sleeving, and overbraiding<\/p><\/li>

  • MIL-spec connector terminations (D-sub, Micro-D, Circular, etc.)<\/p><\/li>

  • Full electrical testing: continuity, Hi-Pot, IR, and signal tests<\/p><\/li>

  • Cleanroom-compliant fabrication and ESD-safe handling<\/p><\/li>

  • Serialization and traceable documentation packages<\/p>

    Whether for satellites, launch vehicles, or high-reliability avionics, Avenir Technologies delivers robust, flight-ready harnesses<\/strong> you can count on\u2014engineered for performance, inspected for perfection.<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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    Custom Wire and Cable Harnesses for Flight, Ground, and Test SystemS<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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    We design and fabricate custom wire and cable harnesses<\/strong> engineered to meet the exacting standards of flight hardware, ground support equipment (GSE), and test systems<\/strong> in the aerospace domain.<\/p>

    Our harnesses are built using space-grade materials<\/strong>, routed and terminated with precision, and tested to ensure reliability in harsh environments<\/strong>, including vacuum, vibration, thermal extremes, and electromagnetic interference (EMI). We support a wide variety of mission applications\u2014from onboard avionics and satellite payloads<\/strong> to launch pad interfaces and automated test setups<\/strong>.<\/p>

    Working closely with engineering teams, we ensure application-specific designs<\/strong> that optimize performance, maintain signal integrity, and comply with NASA, ESA (ECSS), and MIL-STD protocols<\/strong>.<\/p>

    Key Capabilities:<\/strong><\/p>

    • Flight-qualified harnesses with PTFE, ETFE, or Kapton\u00ae insulation<\/p><\/li>

    • EMI-shielded and twisted-pair configurations for noise-sensitive circuits<\/p><\/li>

    • Custom connectorization: D-sub, MIL-C, Micro-D, circular, RF, and fiber optics<\/p><\/li>

    • Ground and test system harnesses built for durability and easy maintenance<\/p><\/li>

    • High-speed data, power, RF, and telemetry cabling solutions<\/p><\/li>

    • 100% electrical testing: continuity, IR, Hi-Pot, and signal integrity<\/p><\/li>

    • Cleanroom-ready assembly and ESD-safe procedures<\/p><\/li>

    • Traceable serialization and full compliance documentation<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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      Shielded, twisted, coaxial, and high-speed data cable integration<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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      We specializes in the integration of advanced cable technologies<\/strong> for aerospace applications, including shielded, twisted-pair, coaxial, and high-speed data cables<\/strong>. Our solutions are engineered to ensure electromagnetic compatibility (EMC), signal integrity, and performance reliability<\/strong> in mission-critical environments\u2014whether in orbit, on the launch pad, or in avionics test labs.<\/p>

      We support the full range of aerospace communication and control systems, from RF and telemetry cabling<\/strong> to space-qualified Ethernet, LVDS, and CAN bus networks<\/strong>. Each assembly is built using space-grade insulation materials<\/strong> and terminated with mil-spec or custom connectors<\/strong>, meeting stringent mechanical and electrical requirements.<\/p>

      Our Integration Expertise Includes:<\/strong><\/p>

      • EMI\/RFI-shielded cable construction and terminations<\/p><\/li>

      • Twisted-pair wiring for noise reduction in control and sensor systems<\/p><\/li>

      • Precision coaxial cabling for RF and video signal transmission<\/p><\/li>

      • High-speed digital cabling: SpaceWire, LVDS, Ethernet, USB, HDMI, and CAN<\/p><\/li>

      • Termination to D-sub, SMA, Micro-D, circular, and custom connectors<\/p><\/li>

      • 100% testing for impedance, continuity, insulation, and signal fidelity<\/p><\/li>

      • Integration into harness assemblies or standalone cable systems<\/p><\/li>

      • Built to ECSS, NASA-STD, and MIL-STD quality and documentation standards<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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        Precision routing, lacing, sleeving, and overbraiding<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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        We provide precision wire and cable management solutions<\/strong> that meet the highest standards of aerospace and defense reliability. Our expertise in routing, lacing, sleeving, and overbraiding<\/strong> ensures that every harness is structurally sound, easy to install, and optimized for long-term performance in high-stress environments.<\/p>

        Our technicians follow NASA-STD-8739.4 and IPC\/WHMA-A-620<\/strong> workmanship standards to achieve clean, consistent cable routing<\/strong> that minimizes stress, abrasion, and electromagnetic interference (EMI). From spacecraft payloads to launch ground systems, we apply mission-specific bundling techniques<\/strong> to ensure thermal stability, vibration resilience, and spatial efficiency.<\/p>

        Our Capabilities Include:<\/strong><\/p>

        • Clean and logical harness routing for tight aerospace assemblies<\/p><\/li>

        • Flat and spot lacing with space-approved lacing tapes and cords<\/p><\/li>

        • Application of high-performance sleeving (PTFE, Nomex\u00ae, fiberglass, etc.)<\/p><\/li>

        • Shielding and overbraiding using stainless steel, tinned copper, or Kevlar\u00ae<\/p><\/li>

        • EMI\/RFI mitigation through conductive jackets and custom shielding solutions<\/p><\/li>

        • Routing and bundling to accommodate thermal and mechanical loads<\/p><\/li>

        • Conformance to ECSS, NASA, and MIL-STD cable management practices<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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          MIL-spec connector terminations<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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          WE offers expert termination and integration of MIL-spec connectors<\/strong>, ensuring robust electrical and mechanical connections for mission-critical aerospace systems. Our capabilities cover a wide range of connector types\u2014including D-sub, Micro-D, circular, rectangular, RF, and fiber optic interfaces<\/strong>\u2014engineered for durability and performance in extreme environments.<\/p>

          We ensure each termination is performed to exacting military and aerospace standards<\/strong> such as MIL-DTL, NASA-STD-8739.4, and IPC\/WHMA-A-620<\/strong>, using precision tools, certified personnel, and controlled environments. Every connection is verified for continuity, insulation resistance, and proper mechanical strain relief.<\/p>

          Connector Termination Services Include:<\/strong><\/p>

          • Integration of MIL-spec and space-qualified connectors<\/p><\/li>

          • Support for standard and custom pin counts, keyed configurations<\/p><\/li>

          • D-sub, Micro-D, MIL-C-26482, MIL-DTL-38999, SMA, TNC, and more<\/p><\/li>

          • High-density, high-speed, and RF connector assembly<\/p><\/li>

          • Soldered, crimped, and epoxy-sealed terminations<\/p><\/li>

          • Torqueing, potting, and strain relief for environmental protection<\/p><\/li>

          • 100% testing for electrical continuity, insulation resistance, and visual quality<\/p><\/li>

          • Full traceability and conformance to ECSS, MIL-STD, and NASA workmanship guidelines<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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            Full electrical testing: continuity, Hi-Pot, IR, and signal tests<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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            We perform comprehensive electrical testing<\/strong> to validate the integrity, reliability, and performance of every aerospace cable assembly and electronic subsystem we deliver. Our rigorous testing protocols ensure full compliance with NASA, ESA (ECSS), and MIL-STD requirements<\/strong>, giving our clients confidence in mission-critical operations.<\/p>

            Each unit undergoes a series of automated and manual tests in our controlled lab environment to detect faults, insulation breakdowns, or signal degradation before deployment. Whether for flight hardware, ground support systems, or test environments, our electrical verification ensures your assemblies meet the most demanding operational standards.<\/p>

            Our Electrical Testing Capabilities Include:<\/strong><\/p>

            • Continuity Testing<\/strong> \u2013 Verifies uninterrupted signal paths across every pin and conductor<\/p><\/li>

            • Hi-Pot (High Potential) Testing<\/strong> \u2013 Confirms dielectric strength and insulation integrity under high voltage conditions<\/p><\/li>

            • Insulation Resistance (IR) Testing<\/strong> \u2013 Measures leakage and insulation quality between conductors<\/p><\/li>

            • Signal Integrity Testing<\/strong> \u2013 Ensures data fidelity in high-speed and sensitive communication lines<\/p><\/li>

            • Custom test harnesses and fixtures for complex multi-connector assemblies<\/p><\/li>

            • Documentation of all test results, serialized per unit for full traceability<\/p><\/li>

            • Testing per IPC\/WHMA-A-620, NASA-STD-8739, and MIL-STD protocols<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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              Cleanroom-Compliant Fabrication and ESD-Safe Handling<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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              We maintain strict protocols for cleanroom-compliant fabrication<\/strong> and ESD-safe handling<\/strong>, ensuring that all aerospace components meet the highest levels of cleanliness, contamination control, and electrostatic protection throughout the production lifecycle.<\/p>

              Our certified cleanroom environments support the assembly, integration, and packaging of flight- and mission-critical hardware<\/strong> with full adherence to ISO 14644 standards<\/strong>. Every technician is trained in ESD prevention<\/strong>, utilizing grounded workstations, antistatic garments, and conductive tools to eliminate the risk of electrostatic damage to sensitive electronics.<\/p>

              Our Cleanroom & ESD-Safe Capabilities Include:<\/strong><\/p>

              • Fabrication and assembly in ISO Class 7\/8 cleanroom environments<\/p><\/li>

              • ESD-safe workstations, packaging, and controlled access zones<\/p><\/li>

              • Ionized air tools, dissipative mats, wrist straps, and conductive flooring<\/p><\/li>

              • Handling of space-grade electronics, connectors, harnesses, and subassemblies<\/p><\/li>

              • Cleanroom-approved materials, gloves, and validated cleaning procedures<\/p><\/li>

              • Regular monitoring for particle count, humidity, and electrostatic levels<\/p><\/li>

              • Compliance with NASA-STD-8739<\/strong>, ECSS-Q-ST-70<\/strong>, and IPC standards<\/strong><\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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                Serialization and traceable documentation packages<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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                We understand that traceability is mission-critical<\/strong> in aerospace manufacturing. Our comprehensive serialization and documentation systems<\/strong> ensure that every component, assembly, and sub-system can be tracked throughout its lifecycle \u2014 from fabrication and testing to final deployment.<\/p>

                We provide unique serial numbers, barcodes, or data matrix identifiers<\/strong> for every deliverable, allowing full visibility into production history, materials, workmanship inspection, and test results. Our documentation packages meet the rigorous requirements of ECSS, NASA, and MIL-STD standards<\/strong>, supporting both quality assurance and regulatory compliance.<\/p>

                Our Serialization & Documentation Services Include:<\/strong><\/p>

                • Unique serialization schemes (alphanumeric, QR code, data matrix) per project requirements<\/p><\/li>

                • Full build history records, including operator logs, material traceability, and lot numbers<\/p><\/li>

                • Digital and physical documentation packages for customer acceptance and audit readiness<\/p><\/li>

                • Test reports, inspection records, and Certificate of Conformance (CoC)<\/p><\/li>

                • Documentation aligned with ECSS-Q-ST, NASA-STD-8739, IPC\/WHMA-A-620, and MIL-STD standards<\/p><\/li>

                • Archiving of all documentation for long-term traceability and support<\/p><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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                  We specialize in the precision fabrication of aerospace-grade wire and cable harnesses, built to meet the rigorous demands of space, avionics, and defense applications. Every harness is engineered with mission-critical reliability, ensuring optimal electrical performance, mechanical durability, and environmental resistance. Our in-house capabilities cover the full lifecycle\u2014from design support and prototyping to high-mix, low-volume production, all under strict adherence to standards such as IPC\/WHMA-A-620, NASA-STD-8739.4, and ECSS-Q-ST-70-26. We use only space-rated materials, including PTFE, ETFE, Kapton\u00ae, and shielded or twisted-pair configurations for EMI-sensitive systems. Each harness is tested for continuity, insulation resistance, and signal integrity, with full traceability and documentation provided for every assembly. Our Harness Fabrication Capabilities Include: Custom wire and cable harnesses for flight, ground, and test systems Shielded, twisted, coaxial, and high-speed data cable integration Precision routing, lacing, sleeving, and overbraiding MIL-spec connector terminations (D-sub, Micro-D, Circular, etc.) Full electrical testing: continuity, Hi-Pot, IR, and signal tests Cleanroom-compliant fabrication and ESD-safe handling Serialization and traceable documentation packages Whether for satellites, launch vehicles, or high-reliability avionics, Avenir Technologies delivers robust, flight-ready harnesses you can count on\u2014engineered for performance, inspected for perfection. Custom Wire and Cable Harnesses for Flight, Ground, and Test SystemS We design and fabricate custom wire and cable harnesses engineered to meet the exacting standards of flight hardware, ground support equipment (GSE), and test systems in the aerospace domain. Our harnesses are built using space-grade materials, routed and terminated with precision, and tested to ensure reliability in harsh environments, including vacuum, vibration, thermal extremes, and electromagnetic interference (EMI). We support a wide variety of mission applications\u2014from onboard avionics and satellite payloads to launch pad interfaces and automated test setups. Working closely with engineering teams, we ensure application-specific designs that optimize performance, maintain signal integrity, and comply with NASA, ESA (ECSS), and MIL-STD protocols. Key Capabilities: Flight-qualified harnesses with PTFE, ETFE, or Kapton\u00ae insulation EMI-shielded and twisted-pair configurations for noise-sensitive circuits Custom connectorization: D-sub, MIL-C, Micro-D, circular, RF, and fiber optics Ground and test system harnesses built for durability and easy maintenance High-speed data, power, RF, and telemetry cabling solutions 100% electrical testing: continuity, IR, Hi-Pot, and signal integrity Cleanroom-ready assembly and ESD-safe procedures Traceable serialization and full compliance documentation Shielded, twisted, coaxial, and high-speed data cable integration We specializes in the integration of advanced cable technologies for aerospace applications, including shielded, twisted-pair, coaxial, and high-speed data cables. Our solutions are engineered to ensure electromagnetic compatibility (EMC), signal integrity, and performance reliability in mission-critical environments\u2014whether in orbit, on the launch pad, or in avionics test labs. We support the full range of aerospace communication and control systems, from RF and telemetry cabling to space-qualified Ethernet, LVDS, and CAN bus networks. Each assembly is built using space-grade insulation materials and terminated with mil-spec or custom connectors, meeting stringent mechanical and electrical requirements. Our Integration Expertise Includes: EMI\/RFI-shielded cable construction and terminations Twisted-pair wiring for noise reduction in control and sensor systems Precision coaxial cabling for RF and video signal transmission High-speed digital cabling: SpaceWire, LVDS, Ethernet, USB, HDMI, and CAN Termination to D-sub, SMA, Micro-D, circular, and custom connectors 100% testing for impedance, continuity, insulation, and signal fidelity Integration into harness assemblies or standalone cable systems Built to ECSS, NASA-STD, and MIL-STD quality and documentation standards Precision routing, lacing, sleeving, and overbraiding We provide precision wire and cable management solutions that meet the highest standards of aerospace and defense reliability. Our expertise in routing, lacing, sleeving, and overbraiding ensures that every harness is structurally sound, easy to install, and optimized for long-term performance in high-stress environments. Our technicians follow NASA-STD-8739.4 and IPC\/WHMA-A-620 workmanship standards to achieve clean, consistent cable routing that minimizes stress, abrasion, and electromagnetic interference (EMI). From spacecraft payloads to launch ground systems, we apply mission-specific bundling techniques to ensure thermal stability, vibration resilience, and spatial efficiency. Our Capabilities Include: Clean and logical harness routing for tight aerospace assemblies Flat and spot lacing with space-approved lacing tapes and cords Application of high-performance sleeving (PTFE, Nomex\u00ae, fiberglass, etc.) Shielding and overbraiding using stainless steel, tinned copper, or Kevlar\u00ae EMI\/RFI mitigation through conductive jackets and custom shielding solutions Routing and bundling to accommodate thermal and mechanical loads Conformance to ECSS, NASA, and MIL-STD cable management practices MIL-spec connector terminations WE offers expert termination and integration of MIL-spec connectors, ensuring robust electrical and mechanical connections for mission-critical aerospace systems. Our capabilities cover a wide range of connector types\u2014including D-sub, Micro-D, circular, rectangular, RF, and fiber optic interfaces\u2014engineered for durability and performance in extreme environments. We ensure each termination is performed to exacting military and aerospace standards such as MIL-DTL, NASA-STD-8739.4, and IPC\/WHMA-A-620, using precision tools, certified personnel, and controlled environments. Every connection is verified for continuity, insulation resistance, and proper mechanical strain relief. Connector Termination Services Include: Integration of MIL-spec and space-qualified connectors Support for standard and custom pin counts, keyed configurations D-sub, Micro-D, MIL-C-26482, MIL-DTL-38999, SMA, TNC, and more High-density, high-speed, and RF connector assembly Soldered, crimped, and epoxy-sealed terminations Torqueing, potting, and strain relief for environmental protection 100% testing for electrical continuity, insulation resistance, and visual quality Full traceability and conformance to ECSS, MIL-STD, and NASA workmanship guidelines Full electrical testing: continuity, Hi-Pot, IR, and signal tests We perform comprehensive electrical testing to validate the integrity, reliability, and performance of every aerospace cable assembly and electronic subsystem we deliver. Our rigorous testing protocols ensure full compliance with NASA, ESA (ECSS), and MIL-STD requirements, giving our clients confidence in mission-critical operations. Each unit undergoes a series of automated and manual tests in our controlled lab environment to detect faults, insulation breakdowns, or signal degradation before deployment. Whether for flight hardware, ground support systems, or test environments, our electrical verification ensures your assemblies meet the most demanding operational standards. Our Electrical Testing Capabilities Include: Continuity Testing \u2013 Verifies uninterrupted signal paths across every pin and conductor Hi-Pot (High Potential) Testing \u2013 Confirms dielectric strength and insulation integrity under high voltage conditions Insulation Resistance (IR) Testing \u2013 Measures leakage and insulation quality between conductors Signal Integrity Testing \u2013 Ensures<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"inline_featured_image":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_joinchat":[],"footnotes":""},"class_list":["post-4753","page","type-page","status-publish","hentry"],"acf":[],"aioseo_notices":[],"_links":{"self":[{"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/pages\/4753","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/comments?post=4753"}],"version-history":[{"count":41,"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/pages\/4753\/revisions"}],"predecessor-version":[{"id":5686,"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/pages\/4753\/revisions\/5686"}],"wp:attachment":[{"href":"https:\/\/avenirtechno.com\/index.php\/wp-json\/wp\/v2\/media?parent=4753"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}