Feature: Aerospace, Military & Defence


maintaining uninterrupted operations in land, sea and space-based systems. Tese include resilience to intense vibrations, high-impact shock forces, temperature extremes, along with protection against excess moisture, dust and contaminants. Equally important, aerospace and defence connectors must withstand hundreds or even thousands of mating cycles without failure. Corrosion from salt spray and oxidation


also can cause rapid deterioration. Te AirBorn report reinforces the need for gold plating to block oxidation and nickel underplating to protect against physical wear.


Cohesive systems ensure long-term reliability According to the AirBorn report, designing connectors for aerospace and defence requires precise alignment of multiple features, from mating cycles to shielding and sealing, as part of a holistic connector ecosystem. A precise balance is needed to combine


capabilities while minimising design trade-offs, whether enhancing sealing, strengthening latching mechanisms or adding more shielding. Ensuring durability over time necessitates


finding and alleviating key failure points while boosting mechanical resilience, environmental adaptability and operational longevity. Te AirBorn report examines the need to optimise Electromagnetic Interference (EMI) shielding and signal integrity under conditions with high electrical noise. Additionally, the report details the role of sophisticated routing strategies that reduce crosstalk and signal degradation over long distances, as well as the importance of advanced shielding to maintain signal fidelity. Sage advice on sustaining stable electrical


connections is offered, including explanations on the long-term impact of engagement length, normal force, plating thickness and manufacturing precision. Additionally, descriptions of ruggedised connectors with multi-point contact systems illustrate the benefits of distributing mechanical loads during conditions of vibration and shock.


Selecting materials for performance and durability Delving into material selection, the AirBorn report explores how choices involving


base alloys, plating thickness and housing material affect mechanical strength, electrical performance and long-term durability. Different materials used for connector contacts, plating and housings are explained, including beryllium copper (BeCu), phosphor bronze, brass, gold, nickel, steel, aluminum alloys, high-performance polymers and composite materials. In addition, the report addresses the


need for radiation-hardened (Rad-Hard) materials in connectors used in satellites, deep-space probes and high-altitude aerospace systems. Built to withstand prolonged exposure to ionising radiation, these specially designed Rad-Hard connectors must resist radiation-induced embrittlement, conductivity loss and atomic oxygen erosion while maintaining reliability in vacuum environments.


Manufactured for mission-critical standard AirBorn’s SInergy modular high-speed hybrid connectors merge high-speed, durability and adaptability into high-density interconnect systems that keep pace with evolving mission needs. Modular product design offers flexibility to configure connectors based on specific requirements, ranging from high-vibration military vehicles to thermally demanding avionics or high-radiation space applications. Te future of next-generation aerospace


and defense systems depends upon continued connectivity advancements. Together, AirBorn and Molex are leveraging decades of experience and specialised expertise to drive ongoing developments of increasingly reliable, rugged solutions capable of sustaining top performance under the most extreme conditions.


www.electronicsworld.co.uk May 2025 31


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