Feature: Connectors & Interconnections
Mission-ready connectors T
must withstand adverse environmental conditions, including extreme temperatures and relentless vibration. From the battlefield to space missions, each component must perform flawlessly. Extreme conditions, from arctic cold
as low as -55°C to desert heat reaching 125°C, demand materials with high thermal stability and low expansion coefficients to prevent warping or cracking. Tese connectors must also endure constant vibration and shock, particularly in environments like aircraſt, armoured vehicles, and missile systems, where any failure could lead to catastrophic consequences. Furthermore, connectors used in
high-altitude or deep-sea environments must function reliably under low- pressure conditions, with levels dropping below 10.1 kPa in high-altitude settings and reaching around 1 MPa in deep- sea depths. Ensuring their electrical properties and material integrity remain intact is critical in these extreme conditions.
24 May 2025
www.electronicsworld.co.uk
By Glenn Piper, Director of Global Product Management, WireMasters Material matters Material selection is a crucial factor in the performance and longevity of Mil-Spec connectors, directly influencing their ability to withstand harsh environments. Circular connectors used for military applications must maintain reliability through extreme temperatures, which requires materials that combine thermal stability with strength and light weight. Aluminium housings, widely used
here is no room for failure in defence and military applications. Connectors, essential to the reliability of military and defence equipment,
in aerospace and ground vehicle applications, are up to 65 per cent lighter than stainless steel alternatives while still offering corrosion resistance. Meanwhile, stainless steel housings provide up to three times the tensile strength of aluminium, making them ideal for jet engine and armoured vehicle applications that experience high vibration levels. Te use of high-grade engineered
plastics, including thermoplastics such as PEEK and PTFE, has expanded in military applications due to their significant weight reduction, oſten cutting component weight by up to 50 per cent compared to metal alternatives, while also offering enhanced resistance to chemicals, moisture, and extreme temperatures.
Securing the right connectors Sourcing mil-spec connectors presents
challenges ranging from navigating complex procurement regulations to managing long lead times. Military technology advancements require connectors that fulfil new requirements including weight reduction and EMI shielding capabilities and environmental contaminant resistance. One of the most common challenges
customers face is the sheer variety of Mil-Spec connectors available. The extensive variety of connector types including circular, rectangular, RF coaxial and fibre optic connectors with different military specifications creates a challenging task when selecting the correct part. The selection process must be precise to achieve system compatibility alongside strict performance and durability standards. Another key challenge is integrating
interconnect considerations early in the design phase. Often, connector selection is overlooked until later stages, leading to compatibility issues, increased costs and redesign delays. By prioritising interconnect decisions from the outset, engineers can optimise system reliability, signal integrity and environmental resilience. Intermateability presents an
additional sourcing challenge. Different
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