Based in Irvine, CA, EMI Solutions specializes in manufacturing standard and customized EMI filtered connectors. The company provides high-performance connectivity solutions for critical applications across military, aerospace, transportation, commercial, and industrial sectors.
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Military Connector Manufacturers
Last updated: January 2026
This directory lists 91 military connector manufacturers across the United States, from standard circular and rectangular MIL-SPEC designs to highly specialized fiber optic and hermetic sealing solutions.
Buyers in this space are often solving critical problems like mitigating the risk of obsolescence in long-lifecycle platforms, upgrading existing systems to support next-generation data rates with high-density interconnects, or ensuring reliable power and signal integrity in extreme environments requiring robust hermetic sealing and advanced EMI/RFI shielding.
The spectrum of suppliers ranges from large, vertically integrated Original Equipment Manufacturers (OEMs) who design and produce proprietary MIL-SPEC series, to specialist contract manufacturers focusing on niche applications like custom cable assemblies or ruggedized COTS modifications, to authorized distributors with value-added assembly capabilities for quick-turn projects. Each type offers distinct advantages depending on the project's scale, complexity, and urgency.
Engaging these manufacturers effectively requires a well-defined Statement of Work, including detailed technical drawings, specified environmental operating conditions, anticipated lifecycle demands, and crucially, all applicable regulatory and quality requirements. Suppliers will expect clear documentation on everything from material compliance to AS9100 certification and traceability mandates.
Company Directory
91 companies nationwide
Based in Endicott, NY, Amphenol Industrial Operations manufactures ruggedized circular power and signal connectors. They provide environmentally protected products, including RADSOK® power contacts, and specialty contacts for high-speed, coax, and fiber optic applications, offering complete value-added solutions.
Based in Fall River, MA, Anderson Airmotive Products Co. manufactures durable ground power connectors, plugs, receptacles, and cable assemblies for commercial and military use. Their products are listed on the Qualified Products List (QPL) AS-7974A/D and meet ISO461-1 / ISO461-2 standards, ensuring robust power connection solutions.
Based in Fairfield, NJ, Armel Electronics, LLC manufactures high-performance connectors for military and defense applications. They also produce MIL-S-12883 compliant relay sockets and standoff terminals for aircraft, communication, and radar systems. Serving aerospace and defense since 1949.
Based in Camarillo, CA, Binder USA, LP manufactures harsh environment and weatherproof cable connectors. The company specializes in robust, high-resistance, and reliable connector solutions, including M8 series connectors for EMC-critical environments. Their products are engineered for demanding outdoor and industrial applications.
Based in Oxnard, CA, BIRNS, Inc. is an AS9100 certified manufacturer of high-performance underwater and subsea connectors and cable assemblies. They offer Millennium Subsea Interconnect Solutions, including high-low voltage, fiber optic, and hybrid options, alongside Meridian connectors for demanding subsea vehicle power transfer.
Based in Newport Beach, CA, Bracke Manufacturing, LLC specializes in manufacturing RF connectors with standard and precision performance levels. These durable connectors are constructed with brass or stainless steel bodies. Their product range includes adapters, attenuators, balanced mixers, and cable assemblies, providing high-quality RF components for various industrial requirements.
Based in Tipp City, OH, Captor Corporation specializes in military electromechanical manufacturing and assembly services. The company produces a variety of critical products, including rigid and flex circuits, tailored for defense applications. They provide comprehensive solutions from design to final assembly, supporting the unique needs of military clients.
Based in Colorado Springs, CO, Carrio Cabling is a USA military cable assembly manufacturer. The company specializes in designing, engineering, and building custom cable assemblies for defense applications. Operating since 1988, they hold ISO 9001:2015 and ISO 13485:2016 certifications, along with CAGE code 1JVJ0.
Based in Irvine, CA, Carr Manufacturing Company specializes in custom wire harness and Mil-spec cable assembly fabrication. They manufacture high-performance solutions for the military industry, designed for harsh and critical environments. The company also provides box build services and custom power supply manufacturing.
Based in Kingston, MA, Caton Connector Corporation manufactures high-voltage connectors and cable assemblies. They engineer customized solutions for critical military, aerospace, industrial, and scientific applications, ensuring reliability. With over 50 years of experience, the company is AS9100 and ISO 9001 certified for quality and performance.
Based in Orange, CA, CCI Coastal is a contract manufacturer of electronic assemblies for aerospace and defense. They provide MIL-SPEC cable assemblies, wire harnesses, and rack integration. Capabilities include potting, laser wire marking, and full electrical testing, supported by AS9100D certification.
Based in Gardena, CA, Centron Industries manufactures high-performance RF connectors. These specialized components are designed for robust applications and are utilized by major military tactical systems.
Based in Stuart, FL, Coaxicom is an ITAR Compliant US manufacturer specializing in American-made RF microwave components. The company produces a range of high-quality connectors, adapters, cable assemblies, and terminations designed for demanding applications, serving various industries that require precision RF and microwave solutions.
Based in Santa Ana, CA, Complete Hermetics custom manufactures glass-to-metal and ceramic-to-metal hermetic seals and feedthroughs. They specialize in hermetic connectors, including MIL-Spec options, for critical applications. Their products serve the defense, medical technology, semiconductor, energy, and aerospace industries.
Based in Torrance, CA, Conesys is a vertically integrated manufacturer of electronic connectors. They specialize in mil-spec circular and rectangular connectors, fiber optic termini, and interconnect systems. Conesys serves Military/Aerospace, Commercial Aviation, and Marine markets, offering standard and customized solutions for demanding applications.
Based in Santa Ana, CA, ICC is a global provider of electronic connectors, cable assemblies, and value-added solutions. The company specializes in designing and manufacturing robust interconnect solutions for demanding military and aerospace applications. ICC offers both standard and custom products, utilizing capabilities like CNC machining and injection molding.
Based in Miamisburg, OH, Connective Design, Inc. is an ISO 9001:2015 certified woman-owned small business. The company manufactures active and passive interconnect products, providing specialized connection solutions for various industrial and commercial applications. Their manufacturing expertise positions them as a direct provider of interconnect solutions.
Based in Toledo, OH, Connectronics Corp. custom manufactures specialized connectors and interconnection systems. They provide solutions for high voltage, high current, and underwater applications, built to exact mechanical and electrical specifications. The company holds AS9100D and ISO 9001:2015 certifications.
Based in Houston, TX, Co-Operative Industries Aerospace specializes in manufacturing custom, hermetically sealed connectors for high-temperature and demanding environments. They also provide wiring harnesses, igniter leads, and flexible conduits. Serving the aerospace and military sectors, the company utilizes glass-to-metal sealing techniques for robust connection solutions.
Corsair Electrical Connectors is a U.S.-based manufacturer of electrical connectors. The company offers vertically integrated solutions, designing and producing robust connectors for mission-critical applications. Serving industrial and commercial sectors, it provides high-performance and reliable connector products engineered for demanding environments.
Cristek Interconnects specializes in designing and manufacturing high-reliability custom and standard connectors for demanding applications. They provide high-density, micro-miniature, filtered, and hermetically sealed interconnects for military, aerospace, space, and medical industries. Based in Anaheim, CA, Cristek offers in-house engineering, machining, and assembly capabilities.
Based in Edinburgh, IN, Connectronics specializes in the manufacturing of RF and microwave connectors and adapters. All parts are proudly made in their U.S. facility, ensuring DFARS and ITAR compliance for critical connectivity challenges, particularly in the defense sector.
Based in Beverly, MA, Delta manufactures precision-engineered, high-performance RF connectors, adapters, and cable assemblies. The company provides innovative RF, microwave, and millimeter wave solutions, qualified to MIL-PRF-55339. Their products are used worldwide in applications requiring unmatched reliability.
Douglas Electrical Components manufactures hermetically sealed connectors, including 5015 series, and custom feedthroughs. Their robust sealing technologies provide unwavering protection for sensitive electronics in demanding aerospace and defense applications across land, sea, and air environments.
EBY Company manufactures custom connectors, cable assemblies, and binding posts. With over 100 years of experience, this American business provides top-quality products for military, medical, aerospace, telecommunications, and commercial requirements, specializing in custom electronic component design and production.
Based in Chatsworth, CA, Electro Adapter manufactures Military and Mil-Spec connector backshells and accessories. Specializing in AS85049 and M85049 series backshells and molding adapters, the company is ISO9001:2015 certified and ITAR Registered. They provide essential components for defense and aerospace applications.
Elimec USA manufactures specialized connectors for military tactical networks, complying with GAM T2 and GAM T1 standards. Their robust connectors offer IP68 sealing for harsh environments, operating reliably across a wide temperature range from -55°C to +125°C for critical military applications.
Amphenol Fiber Systems International produces and supplies fiber optic connectors for military applications. The company provides specialized connectivity solutions to the US Navy and various naval allies globally, supporting critical defense systems.
GET Engineering designs and assembles a comprehensive line of military cables and connectors in-house, tailored to interface with MIL-STD-1397C adapters and HDIO products. The company provides innovative communication solutions, including NTDS, I/O, and High Density Input Output (HDIO) systems, alongside compact embedded systems for defense and industrial applications.
Based in Glendale, CA, Glenair, Inc. specializes in manufacturing high-reliability connectors and cables. These critical interconnect solutions are designed for demanding land, sea, air, and space applications, serving the military and other sectors requiring robust performance.
GMI Corporation is a contract manufacturer specializing in high-performance RF/Microwave cable assemblies, custom harnesses, and coaxial connectors. Based in Westborough, MA, the company supplies these components for military, aerospace, and telecommunications applications, serving as an approved vendor for major defense contractors.
HiRel Connectors Inc. manufactures highly reliable electrical connectors and cable assemblies. They specialize in hermetic and MIL-SPEC interconnect products for military, aerospace, and mission-critical systems including aircraft, engines, spacecraft, and missiles. The company offers a patented self-locking mechanism for extreme vibration applications.
IEH Corporation, based in Allentown, PA, engineers and manufactures high-performance connectors primarily for military, aerospace, and industrial applications. Utilizing Hyperboloid contact technology, the company ensures superior electrical performance and reliability. All connectors are proudly engineered and manufactured within the USA.
ITT Cannon manufactures high-performance, Mil-Spec connectors for military, defense, and aerospace systems. They provide robust connectivity solutions for military aviation, soldier systems, ground vehicles, and missiles. Their MKJ Warrior Series is qualified to Nett Warrior by the US Army.
JACO Machine Works, based in Scotts Valley, CA, is an ISO9001:2015 and AS9100D certified manufacturer. They specialize in precision custom CNC machining services, including 5-axis and screw machining. The company produces critical components and assemblies for high-performance electrical connectors, delivering accurate, high-quality results for industrial applications.
Based in Painesville, OH, Joy Signal Technology, LLC. manufactures custom cable assemblies for OEMs across various electronics markets. They specialize in ruggedized interconnects, including patented Compact Brute Connectors with hermaphroditic contacts, and offer advanced Coaxial Ribbon Cable mass termination capabilities.
kSARIA designs, manufactures, and installs mission-critical interconnect solutions for defense and aerospace industries. They specialize in fiber optic, copper, and custom cable assemblies, alongside military-grade connectors, adapters, and components. All manufacturing occurs in their ISO9001/AS9100D certified US facility in Hudson, MA.
LeeMAH Electronics, based in Brisbane, CA, is a contract manufacturer specializing in custom cable and electronic assemblies for the Aerospace/Defense industry. Their services include PCBA, box build, and testing, all meeting Mil-spec standards and supported by AS-9100D, ISO:9001-2015, and ITAR registration.
Based in Austin, TX, Megladon Manufacturing provides high-quality fiber optic solutions and customized products. They offer on-site engineering and manufacturing for diverse industrial and military connector and cable types. The company utilizes patented HLC® technology to deliver precise, reliable endface termination.
Based in Painesville, OH, Meritec manufactures custom high-performance interconnect systems. The company supplies specialized custom military cables and connectors to numerous Mil/Aero/Marine contractors, providing tailored interconnection solutions for critical defense and aerospace applications across many divisions.
Based in Lewisville, TX, MilesTek offers MIL-STD-1553 and Ethernet connectivity products for military, aerospace, industrial, and government agencies. This includes military-grade connectors, custom cable assemblies, and data bus couplers. They provide in-stock MIL-STD-1553 Cinch equivalent components, with many items available for same-day shipping.
Milnec Interconnect Systems designs and manufactures heavy-duty, ruggedized circular connectors built to strict mil-spec specifications. They provide complete interconnect systems, backshells, and sealing accessories for demanding military, aerospace, and industrial applications. These COTS solutions support advanced weapons systems, ensuring 100% form, fit, and function compatibility.
MilSpecWest, based in Elkin, NC, manufactures, assembles, and distributes micro connectors, including 5015 and 26482 style connectors. Their products meet or exceed all military specifications, offering a comprehensive inventory of micro circular, push-pull, and coaxial connectors for various industrial and defense applications. The company operates with CAGE Code 8NHG3.
Based in Irvine, CA, Min-E-Con designs and manufactures high-density microminiature connectors, including their 'Nano' series. They provide MIL-DTL-83513 compliant components for military, aerospace, and avionics industries. The ITAR Registered and ISO9001:2015 certified company focuses on product quality and on-time delivery.
MJM Industries is an ITAR-compliant contract manufacturer specializing in custom overmolded cable and wire harness assemblies, including M8/M12 connectors and coaxial cable assemblies. They provide intelligent engineering and innovative manufacturing, focusing on quality and reliability. Services encompass robotic soldering, ultrasonic welding, and custom tooling and fixture design.
Based in Chatsworth, CA, NewVac LLC is an American defense interconnect manufacturer. They specialize in military connectors, cable assemblies, and custom enclosures using build-to-print and reverse engineering. The company provides critical interconnect solutions for defense, aerospace, naval, and ground systems.
Based in Maple Grove, MN, Nortech Systems specializes in designing and manufacturing complex electromechanical systems, assemblies, and components. The company provides vertically integrated solutions, including wire, cable, and interconnect assemblies, and flexible circuits for aerospace, defense, and military applications, ensuring reliability in challenging environments.
Based in Minneapolis, MN, Omnetics Connector Corporation designs and manufactures highly reliable micro-miniature and nano-miniature electronic connectors and interconnection systems. With over 30 years of experience, the company is AS9100 Certified and listed in QPL-32139 and QPL-83513, serving demanding applications.
Based in Dayton, OH, PAVE Technology manufactures highly reliable hermetic electrical feedthroughs and connectors. Their products are pressure and vacuum rated, designed for long-term lifetime use in demanding environments. They offer a wide variety of terminations, voltage, and current capacities, including quick ship options for specialized applications.
PIC Wire & Cable manufactures D38999-style MACHFORCE connectors designed for rugged military applications. They also provide specialized cabling solutions, connectors, and contacts for aerospace and defense electronics, supporting RF, video, and data transmissions. The company is ISO 9001 and AS9100 certified.
Based in Bohemia, NY, Power Connector, LLC (PCI) is an ISO 9001:2015 certified manufacturer of tactical communication interconnects. PCI specializes in standard and custom MIL-DTL compliant power and audio connectors, including MIL-DTL-55181, MIL-DTL-55116, and MIL-DTL-10544 series for military and homeland security applications.
Based in Laguna Niguel, CA, QPC Fiber Optic, LLC specializes in designing and manufacturing fiber optic connectors and cable assemblies. They provide robust connectivity solutions for harsh environments, serving the military and industrial sectors. With extensive experience in challenging fiber optic applications, QPC focuses on high-performance solutions.
Based in Warrington, PA, Rebling manufactures high current connectors and custom molded parts for diverse applications. All products are proudly made or assembled/molded in the USA using American and imported components. They specialize in providing robust connector solutions suitable for demanding environments.
Based in San Diego, CA, Lighthorse Technologies Inc. manufactures a full line of quality RF connectors, RF cable assemblies, and antennas. They offer custom coaxial cables and connectors, covering a wide range of frequencies from DC to 70 GHz, designed to meet specific application requirements.
Sealtron manufactures hermetic connectors, offering commercial and military hermetic circular connectors for a wide range of applications. They provide QPL-certified products for military specifications and European aerospace qualified connectors. Serving Aerospace, Defense, Space, and Industrial markets, Sealtron focuses on high-quality, customizable solutions.
Sullins Connector Solutions manufactures high-reliability card edge connectors, test sockets, and headers, featuring gold-plated contacts for demanding applications. Based in San Marcos, CA, the company specializes in custom-designed parts and offers expedited samples and fast delivery for robust interconnect solutions.
Switchcraft is a U.S. manufacturer of connectors, jacks, plugs, and molded cable assemblies designed for harsh environments. They offer custom product design and manufacturing services for diverse industries, including medical, transportation, and homeland security, all built in the USA for quality and streamlined supply chains.
Winchester Interconnect Micro designs and manufactures precision engineered Micro D, Nano, and circular connectors. The company specializes in MIL-DTL-83513 connectors and offers solutions for critical designs. It holds ISO 9001:2015, ITAR, and AS 9100 certifications.
Phase 3 manufactures and supplies durable single pole and circular power connectors, serving military, government projects, and aerospace. They produce heavy-duty plugs, connectors, and receptacles designed for harsh environments. These industrial devices safely connect electrical power up to 800A, featuring secure, mechanically keyed and locked mating systems.
Based in Dallas, TX, Wallace Electronics is a woman-owned manufacturer specializing in custom cable assemblies, electronic enclosures, and wiring harnesses. They provide D-Sub connectors, ribbon assemblies, and other custom cables. Serving the military, industrial, medical, automotive, and telecom sectors, Wallace Electronics offers over 40 years of expertise.
XACT Engineered Manufacturing Solutions specializes in designing and manufacturing high-reliability cable assemblies and custom product solutions. Their capabilities include military assemblies and DAGR accessories, serving a variety of industries. The company operates a manufacturing facility in Houston, equipped with cutting-edge technology.
Based in Cleveland, OH, Assembly Specialty Products, Inc. manufactures custom wire rope cable assemblies, swaged fittings, studs, connectors, and terminals. The company designs and produces swaged assemblies, including OEM flight control cables for commercial and military aircraft and equipment. It maintains ISO 9001:2015 certification.
Based in Suwanee, GA, Sienna Corporation manufactures custom cable and wire harness assemblies, covering commercial and Mil-spec applications and designs. The company provides vertically integrated manufacturing solutions including PCB assembly, sheet metal fabrication, machining, and injection molded plastics, serving aerospace, healthcare, and industrial sectors.
CDM Inc. manufactures rugged tactical communications cables designed for vehicle and manpack platforms. These American-made cable assemblies incorporate MIL-DTL-55181/55116 military-grade connectors, adhering to AS9100/ISO quality standards. Based in Turnersville, NJ, the company specializes in critical connectivity solutions for defense applications.
Based in Houston, TX, XACT Technologies USA is an AS9100-certified and CMMC Level 2-compliant manufacturer. The company specializes in designing and producing custom cable assemblies and interconnect solutions, including military assemblies and DAGR accessories, primarily serving the defense industry.
Based in Schiller Park, IL, Amerline manufactures high-reliability circular connectors and accessories. The company has supported military programs, including HumVees, for over 40 years, applying these robust standards to industrial and commercial applications. Amerline specializes in NATO, AEC, and Ordnance connectors.
Cicoil Corporation designs and manufactures custom flexible flat cables and complete cable assemblies, integrating connectors for mission-critical military and aerospace applications. They provide value-added services including over-molding, sealing, and potting, all produced in their US-based facility.
Based in Washington, DC, Cinch designs, manufactures, and tests highly reliable interconnect solutions specifically for defense applications. With over 60 years of expertise, the company provides rugged connectors engineered for demanding military environments, serving the defense sector with robust and custom components.
Based in Tinton Falls, NJ, Delaire USA manufactures a complete line of high-quality RF connectors, adapters, and custom cable assemblies. The company produces components to MIL-PRF-39012 military standards, providing robust interconnect solutions for various industries from its US facility.
DEM Manufacturing provides durable, custom cables and connectors built for rugged and demanding applications. As a U.S.-based manufacturer with a CAGE code, they offer comprehensive product development from design and prototyping to production. They specialize in high-precision products for diverse needs.
Based in Tulare, CA, EZ Connector, Inc. designs and manufactures high-reliability magnetic electrical connectors. Specializing in durable solutions for harsh environments, they serve various industries, including government agencies and military equipment, offering both standard and custom-designed connectors.
Fiber Instrument Sales (FIS), based in Oriskany, NY, specializes in manufacturing robust fiber optic cables and custom assemblies for the military. Their solutions incorporate high-performance, military-grade connectors, designed to withstand harsh environments, crush, impact, and cable twist. FIS provides integrated connectivity products tailored for demanding defense applications.
Gore manufactures robust, low-profile aerospace connectors designed for flexible microwave cable assemblies, offering high-performance solutions for demanding environments. The company also provides high-speed data cables and components for high-voltage applications, serving industries like aerospace, EV, and industrial sectors.
Mitas Electronics, based in Austin, TX, custom engineers and manufactures miniature high-speed cables and interconnects. They provide scalable solutions for critical applications in aerospace, defense drones, and high-speed data systems. The company supports initial design through high-volume manufacturing with a global supply chain.
Based in Charlotte, NC, NorComp manufactures premium interconnect solutions, including D-Sub, Micro-D, circular, and custom connectors. The company's products are certified for rugged environments and are explicitly designed for various applications, including Mil-Cots (military commercial off-the-shelf), medical, robotics, and industrial automation sectors.
Optical Cable Corporation (OCC) designs and manufactures specialized military connectors, including COTS M83526 fiber optic and electrical connector families for harsh environments. They offer high-performance connectivity solutions, providing robust fiber optic termini and electrical contacts. With over 30 years of innovation, OCC serves demanding industrial and defense applications.
Based in Milpitas, CA, Onanon manufactures application-specific connectors and cable assemblies. The company provides custom interconnect solutions, including designs with embedded electronics for digital scalability. Onanon serves demanding markets such as medical devices, electromechanical agricultural equipment, and electric transport, highlighting their robust engineering capabilities for high-reliability applications.
Based in Xenia, OH, SPI Connects manufactures military and commercial interconnect products. The company serves the U.S. Military with QPL products, as well as Industrial, Traffic Control, and Oil & Gas markets. They provide standard products and custom-designed interconnect solutions to improve quality and reduce costs.
Based in Richmond, VA, Cables Plus USA manufactures Mil-SPEC fiber optic cable assemblies, specializing in D38999, M28876, and M83526 (TFOCA) connectors. They provide ruggedized MPO/MTP cables for military tactical field use, are ISO 9001:2015 certified, and Telcordia GR326 compliant.
Tacticom USA designs, manufactures, and supplies military ground tactical communications equipment, specializing in accessories, components, and connectors. Established in 1981, they provide connectors for military man-pack and vehicular radios, along with telephone equipment, serving government and industry clients with a substantial inventory for urgent delivery needs.
Teledyne Reynolds US specializes in manufacturing high-voltage interconnect solutions for critical applications. The company develops robust products tailored for demanding military, aerospace, and defense electronics sectors. They also provide specialized interconnects for industrial, medical, energy, and space applications.
Based in Warminster, PA, Z-Axis Connector Company designs and manufactures high-performance elastomeric connectors for demanding applications. Specializing in flexible, miniature, and solder-free interconnect solutions, their Made in the USA products serve critical sectors, including defense and advanced radar systems, with rapid prototyping.
AMETEK AEGIS manufactures a line of hermetic, push-on, and blind-mate radio frequency connectors, including SMP, SMPM, and SMPS interconnects. They also produce custom hermetic electronic packaging and feedthroughs. Their products are designed for the defense sector and high-reliability, mission-critical applications.
AMETEK SCP manufactures specialized electrical, fiber optic, and hybrid hull penetrators and outboard cable assemblies. It delivers advanced underwater fiber optic connector and cable solutions. With extensive experience in international and domestic defense programs, AMETEK SCP serves naval and defense market applications for challenging requirements.
Based in Houston, TX, Hermetic Seal Corporation manufactures custom hermetic and bulkhead connectors with glass-to-metal sealed solutions. Engineered for high-pressure, high-temperature (HPHT) environments, their products serve military, aerospace, and subsea applications. They offer reliable components for mission-critical systems, meeting MIL-DTL-26482 standards.
LEMO USA Inc. is a leading manufacturer specializing in high-quality, high-performance interconnect solutions. The company researches and produces robust and reliable connectors, delivering advanced products designed to exceed current requirements and anticipate future needs for demanding applications, including those within the military sector.
Qnnect specializes in high-performance interconnects, hermetic packaging, and custom connectors for critical connectivity challenges. Its business units manufacture military spec-grade and aerospace connectors, including micro-miniature and RF types. The company serves Mil-Aero, medical, and energy sectors with advanced solutions.
Radiall designs and manufactures high-performance multipin connectors specifically for civil and defense aerospace markets. Based in Tempe, AZ, the company provides robust connectivity solutions crucial for military systems, ensuring reliability in demanding environments. They offer extensive expertise in custom design and precision engineering.
Based in Bartlett, IL, Senior Flexonics manufactures custom thermal management and fluid conveyance solutions, including heat exchangers, metal bellows, and flexible connectors. The ITAR compliant company develops innovative metal bellows sub-assemblies and flexible tubing for diverse land vehicle and specialty product applications.
Winchester Interconnect designs and manufactures interconnect solutions for demanding space, military, medical, and industrial applications. They provide globally certified, high-performance connectors engineered for mission-critical systems. The company specializes in delivering robust and reliable connectivity products tailored to specific customer needs across diverse high-tech industries.
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How to Choose a Company
- Verify the manufacturer holds current AS9100 certification and, for critical applications, is listed on the Defense Logistics Agency's (DLA) Qualified Products List (QPL) for the specific MIL-DTL series you require, such as MIL-DTL-38999, which assures adherence to rigorous military performance standards.
- Insist on evidence of in-house or third-party qualification testing that meets or exceeds the specified environmental and mechanical performance per MIL-STD-810 for shock, vibration, temperature cycling, and corrosion resistance, particularly for harsh operational environments like naval or aerospace applications.
- Evaluate their long-term component availability strategies and their ability to manage obsolescence for the expected platform lifecycle. Understand if they primarily supply COTS (Commercial Off-The-Shelf) solutions, which may have shorter lifecycles, or offer robust build-to-spec options with extended support commitments.
- Confirm their proven track record and internal controls for compliance with International Traffic in Arms Regulations (ITAR) and Export Administration Regulations (EAR) for all components and technical data, especially if your end-use or supply chain involves international partners or destinations.
- Be wary of suppliers promising expedited lead times for QPL-listed components without demonstrating direct line-of-sight to raw material supply or current DLA qualification status. Unrealistic commitments often signal a broker masquerading as a manufacturer, or a lack of understanding of the rigid MIL-SPEC procurement process.
Frequently Asked Questions
What does a manufacturer's DLA QPL listing truly signify for my military connector project?
A DLA Qualified Products List (QPL) listing means the manufacturer's specific product, built to a particular MIL-DTL specification (e.g., MIL-DTL-38999 Series III), has undergone rigorous government-controlled testing and audit processes. It's not just a quality stamp; it certifies that the connector design, materials, manufacturing process, and performance consistently meet the exact military specification, minimizing risk and ensuring interchangeability. Always verify the specific series and part numbers are on the QPL, as a manufacturer may be QPL for one product but not another.
How critical is ITAR compliance when sourcing military connectors, especially for non-US end-users?
ITAR (International Traffic in Arms Regulations) compliance is absolutely critical. Military connectors, particularly those designed for defense applications, often fall under the US Munitions List (USML) category XI. Any export, transfer, or even disclosure of technical data to foreign persons (even within the US) without proper authorization can lead to severe penalties. Manufacturers must have robust ITAR compliance programs, and buyers, especially those with international projects or partners, must ensure their own internal controls align to prevent unauthorized access or export. Always discuss your export control requirements upfront.
What are the key considerations when migrating from legacy MIL-SPEC connectors to newer, higher-performance alternatives?
Migrating requires careful consideration beyond simple form, fit, and function. You must evaluate interoperability with existing wiring and equipment, ensure the new connector meets or exceeds the environmental and electrical performance of the legacy part (e.g., EMI shielding, vibration resistance, current rating), and account for potential requalification costs. Newer alternatives might offer advantages like higher density, reduced weight, or improved bandwidth, but thorough system-level validation, potentially involving MIL-STD-202 testing, and a clear obsolescence management plan for the legacy component are essential.
What kind of environmental testing and validation should I expect for connectors designed for harsh military applications, beyond standard commercial ratings?
For harsh military applications, expect testing far beyond typical commercial specifications. This includes stringent MIL-STD-810 environmental testing for temperature shock, extreme hot/cold operation, humidity, salt fog corrosion, and high-level vibration and mechanical shock. Electrical performance under these conditions is also paramount, verifying contact resistance, insulation resistance, and dielectric strength. Many military connectors also require testing for EMI/RFI shielding effectiveness per MIL-STD-461, and often hermetic sealing verification for pressure differential applications. Always review the supplier's detailed qualification test reports.