This study proposes innovative wire harness bending manufacturing processes and fatigue test platforms to address the issue of wire breakage caused by bending stress during aircraft wire harness assembly. Through modeling analysis, the impact of wire harness bending length changes on internal wire core stress is clarified, and optimized manufacturing processes are designed to reduce the risk of wire breakage effectively. Simultaneously, the developed fatigue test platform can simulate different bending conditions, verifying the reliability and effectiveness of the new processes. This technology addresses manufacturing challenges under assembly space constraints and bending requirements, improving the flexibility and assembly quality of wire harnesses by reserving process allowance and optimizing bending molds. Experimental results show that the improved wire harnesses exhibit higher fatigue resistance during simulated docking tests, significantly reducing damage and providing a strong guarantee for the safety and reliability of aircraft wire harnesses. This research not only provides new solutions for the field of aircraft wire harness manufacturing and assembly but also has significant implications for improving the overall performance and safety of aircraft.