Supplement: Interconnection Fail-safe sourcing
Interconnect solutions are fundamental to the functional integrity of high-reliability systems. They define the electrical, mechanical and environmental interfaces that enable subsystems to operate cohesively under extreme conditions. As systems become more compact, electrified and compliance-driven, the task of sourcing interconnects has evolved into a critical engineering responsibility. Here, Glenn Piper, global director of product management at interconnect specialist WireMasters, explores the challenges of sourcing connectors for high-reliability industries.
S
ourcing the right interconnects is a foundational engineering decision. A well-specified connector enables consistent performance across operating conditions, simplifies certification pathways and reduces risk during integration, testing and field maintenance. In contrast, a poorly chosen one can introduce bottlenecks that are difficult and expensive to fix downstream.
When sourcing goes wrong One of the most frequent and costly mistakes in sourcing connectors for high-reliability applications is delaying their selection until late in the design cycle. Early design phases often focus on system functionality,
32 June 2025
PCB layout and component integration, with interconnects treated as secondary or assumed to be easily specified later. But by the time the electrical and mechanical designs are finalised, key physical constraints, such as mounting location, available space, termination styles and enclosure dimensions, have already been set. This leaves engineers with limited flexibility and often forces last-minute compromises.
In many cases, this forces teams to select connectors based on immediate availability rather than long-term suitability, leading to the use of commercial-grade parts in mission-critical applications.
Another commonly overlooked challenge Components in Electronics
is the complexity of the parts themselves. Military-standard (Milspec) connectors, while designed for rugged performance and standardisation, are highly configurable platforms. Each series can include hundreds of thousands of permutations, with variables such as shell size, plating, contact arrangement, polarisation, material composition and termination method. This complexity increases the risk of missteps, where a minor error in specifying the insert or finish can lead to incompatibility, non-compliance or supply issues. Such mistakes are especially costly in programs requiring multi-sourcing, NATO or DoD standardisation, and strict documentation. Engineers may also unknowingly
select components facing obsolescence or regulatory restrictions, leading to delays, requalification or even full system redesigns under pressure.
How to get it right
Avoiding the most common sourcing pitfalls starts with shifting how teams think about interconnects in the design process. Rather than approaching connectors as a final step after core system components have been locked in, engineers should treat them as integral to the system architecture from the outset. Getting it right also means looking beyond the datasheet. Manufacturers may provide detailed specifications,
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