Rugged and Ready

Connectivity needs balance many, sometimes competing, factors. First and foremost, today’s interconnects must function reliably in a wide range of environmental conditions. In addition to being rugged, they must be smaller and lighter, energy efficient and sustainable, easy to install (or have a long lifespan), and be cost effective. In our latest eBook, Rugged and Ready for the Elements: Harsh environment technologies and ruggedized products, connector suppliers share their knowledge of interconnects for harsh environment applications.

MAY 2026

RUGGED AND READY

Harsh Environment Technologies and Ruggedized Products RUGGED AND READY

John Bishop Managing Director

Connectivity needs balance many, sometimes compet- ing, factors. First and foremost, today’s interconnects must function reliably in a wide range of environmental conditions. In addition to being rugged, they must be smaller and lighter, energy efficient and sustainable, easy to install (or have a long lifespan), and be cost effective. In our latest eBook, Rugged and Ready for the Elements: Harsh environment technologies and ruggedized products, connector suppliers share their knowledge of interconnects for harsh environment applications.

Amy Goetzman

Managing Editor

AJ Born

Associate Managing Editor

Raine Arzola

Creative Director

TABLE OF

CONTENTS

MAY 2026

Failure is Not an Option

Environments with Robust Connectivity 48 Bulgin Data Centers Under Pressure: Designing Infrastructure for an AI-driven Future 45 PEI-Genesis AI Changes the Connectivity Game

Designed to Survive: The Critical Role of Connectors in Harsh Environments 07 Kensington Electronics Inc. The Art and Science of Failure Prevention 13 Molex

AI Without Limits: Enabling Operations in Harsh

The Right Interconnects for Your Application

Exploring Harsh Environment Interconnects

Built to Last: Rugged Interconnect Solutions for Heavy Equipment in Harsh Environments 18 EDAC Group of Companies Robust and Reliable Connectivity: The Engine Behind Precision Agriculture 22 TE Connectivity

Pushing the Boundaries: Adapting Interconnects to Harsh Environments 52 Axon’ Cable Optimizing Connectors for Harsh Environments 55 COAX Connectors

with IEC 58

Standardizing M17 Connectors in Accordance

Beyond IP Ratings: What Oilfield Engineers Need from Their Connectors (How Distributors Help Them Get There)

Phoenix Contact

TTI Inc. Framing the Shift to 48V 29 TE Connectivity

Copper or Fiber Optics? Navigating the Interconnect Dilemma in Harsh Environments 61 Nicomatic Single-Pair Ethernet at Scale: Enabling the Next Generation of Harsh Environment Interconnects 64 Winchester Interconnect

Designing for Durability: Next-Gen Sealing Solutions for the Rise of Outdoor Charging 34 Anderson Power The Right Interconnects for Your Environment

Rectangular Connector 69 Weidmüller USA

Rugged and Resilient: Meet the IP68

Turning Up the Heat 41 Weather Conditions 37 Neutrik Americas

Waterproof Connectors: Ready for Not-So-Fair

Beyond the Factory Floor: The Expanding Role of Industrial Ethernet Connectors 72 Hirose Electric USA

Omnetics Connector Corporation

Product Briefs 76

CONTRIBUTORS

FAILURE IS NOT AN OPTION

The Critical Role of Connectors in Harsh Environments DESIGNED TO SURVIVE:

Casey Cavender CFO

Kensington Electronics Inc.

during bench testing but resurfaces in the field. A systems engi - neer responsible for unmanned platforms once summarized it bluntly: “When the connector fails, the system doesn’t degrade gracefully—it just stops.”

Harsh environments leave no margin for error. Whether deployed deep underwater, high in the sky, inside surgical equipment, or on the battlefield, connectivity must perform flawlessly under extreme conditions. Exposure to vibration, shock, temperature extremes, moisture, chemicals, and electromagnetic interference turns a simple interconnect into a mission-critical component. From aerospace and defense systems to medical devices, industrial automation, and offshore energy applications, connectors are expected to maintain signal integrity, power delivery, and mechanical stability where failure can mean mission loss, safety risks, or catastrophic downtime. In these environments, reliability isn’t a feature, it’s a requirement. When connectivity fails: real-world consequences In harsh environments, connector failures rarely announce themselves clearly. They often appear as intermittent faults—mo- mentary signal losses, unexplained resets, or degraded performance that disappears

Defense platforms and security systems: designing for mission continuity In defense and security applications, a connector that loosens un- der vibration can instantly cut off live video or sensor data from an unmanned ground vehicle, leaving operators blind mid-mission. In mining and heavy industrial automation, a failed interconnect can shut down equipment thousands of feet underground, turning a small component issue into prolonged and expensive downtime. In these systems, connectors are often required to support high- speed data, power, and control signals simultaneously, while main- taining mechanical stability under constant vibration and shock. Backplane and embedded system architectures used in mission computers, vehicle electronics, and ruggedized control units place additional demands on connector design, particularly in terms of signal integrity and retention force.

Fischer Connector’s USB-C

The evolution of USB-C in harsh environments un - derscores a broader reality: vibration and shock, not bandwidth, remain the dominant threats to reliable connectivity. One example of how this challenge is being addressed can be seen in ruggedized USB-C connector designs developed by Fischer Connectors. By integrating mechanical locking approaches originally developed for harsh environments, such as ratcheting-style re- tention mechanisms, ruggedized USB-C solutions can preserve full USB-C functionality, including high-speed data transfer, video transmission, and power delivery, while meeting military and industrial environmental requirements. “ The rise of USB-C as a universal interface for data, video, and power transmission has introduced a new challenge in harsh environments

Smiths Interconnect, KVPX+ Series

One example of an engineering response to these chal- lenges can be seen in ruggedized backplane connector solutions such as the KVPX+ Series from Smiths Inter- connect. Designed for defense and harsh-environment embedded systems, KVPX+-style connectors address the need for high-density, high-speed data transmission while maintaining mechanical robustness in applications exposed to sustained vibration and impact. “When connectivity is carrying situational awareness or control data, even a momentary interruption can have outsized consequences,” one defense systems engineer noted. The rise of USB-C as a universal interface for data, video, and power transmission has introduced a new challenge in harsh environments. While USB-C offers clear advan - tages in terms of performance and interoperability, its origins in commercial electronics mean that standard implementations are not inherently suited for sustained vibration, shock, or field handling common in military and industrial systems. In defense vehicles, unmanned platforms, and rugge- dized industrial equipment, USB-C connections may be used to support high-speed data links, video feeds, or power delivery to mission electronics. In these applica- tions, maintaining secure mating and signal integrity under vibration becomes just as critical as electrical performance.

“The interface itself isn’t the problem,” one systems engineer observed. “It’s making sure it stays connected when the environment is doing everything it can to pull it apart.” This evolution reflects a broader trend across defense and industrial sectors: adapting familiar, high-performance interfaces to environments where mechanical security and reliability are as important as bandwidth or convenience. While defense and security systems often emphasize mission electronics and situational awareness, many of the same vibration-driven challenges extend directly into military vehicles and heavy industrial platforms.

Fischer Connectors, UltiMate Series

One engineering approach to this challenge can be seen in ruggedized connector designs that incorporate mechanical locking systems intended to resist loosening under dynamic loads. For example, Fischer Connectors has applied a ratcheting-style locking mechanism in its UltiMate series to address environments where vibra- tion-induced unmating is a primary failure mode. In the UltiMate size 15 contact configuration, this ap - proach supports up to 27 contacts within a receptacle measuring 25.8 mm in diameter, while withstanding random vibration levels of up to 37.8 gRMS, exceeding the vibration profiles encountered in most ground vehicles and many aerospace applications. The same configuration is also designed to tolerate shock loads of up to 300 G, reflecting the impulsive forces common in off-road mobility, rail transport, and heavy industrial equipment. Importantly, this level of mechanical robustness does not come at the expense of usability. Locking mech - anisms intended for harsh environments must bal- ance retention force with intuitive operation. In field conditions, connectors that require excessive force or complex actions to mate can slow maintenance and in- crease the risk of improper engagement. “If a connector can’t be connected correctly the first time in the field,” a systems integrator noted, “its vibration rating doesn’t really matter.” By enabling secure mating and unmating through a simple rotational motion, ruggedized locking designs allow operators to establish reliable connections quickly and confidently, even in tight spaces or under adverse conditions. This balance between mechanical security and human factors is a recurring theme in successful military and mining system designs.

Military vehicles and mining systems: designing for continuous vibration and impact Military vehicles and mining systems operate in envi- ronments where vibration and shock are not occasion - al stressors, they are constant operating conditions. Tracked and wheeled military platforms, rail systems, and heavy mining equipment generate continuous vibration combined with sudden impacts from terrain, recoil, or material handling. Over time, these forces can loosen traditional locking mechanisms, leading to inter - mittent electrical contact that is difficult to detect during testing and even harder to diagnose in the field. “The worst failures aren’t total failures,” one field engineer explained. “They’re the ones that flicker just enough to make you chase ghosts.” In these applications, connectors must maintain me- chanical engagement and electrical continuity despite sustained vibration, repeated shock events, and fre - quent handling during maintenance or reconfiguration. Ease of use is also critical, as connections are often made in confined spaces, under poor visibility, or while operators are wearing gloves or protective gear.

Smiths Interconnect, D Series

Why contact technology matters in sterilized environments Repeated autoclave exposure—commonly reaching temperatures around 250 °F (121 °C) for extended du- rations—introduces thermal stress, moisture ingress risk, and material fatigue. Traditional contact designs can lose spring force over time, leading to increased contact resistance or intermittent connections.

Medical devices: reliability under sterile, repetitive stress Medical equipment presents a unique harsh-environ- ment challenge. In addition to mechanical reliability and electrical performance, connectors must withstand re- peated sterilization, strict size constraints, and intuitive operation in clinical settings where ease of use directly impacts patient safety. One real-world example comes from the field of elec - trophysiology, where a medical device manufacturer sought an alternative to traditional high-cost, auto- clave-compatible connector solutions. The application involved electrophysiology catheters used to map the electrical activity of the heart to detect arrhythmias. These minimally invasive procedures access the heart through a small incision—typically in the groin—thread- ing a disposable catheter through blood vessels rather than relying on open-heart surgery. The approach sig- nificantly reduces patient recovery time, but it places demanding requirements on the supporting hardware. In this case, the connector needed to support up to 82 contacts in a compact form factor, deliver consistent electrical performance, and survive multiple autoclave sterilization cycles without degradation. Ease of use was equally critical, as clinicians rely on fast, reliable connections in time-sensitive environments. “In medical devices, connector failure doesn’t just mean downtime,” one biomedical engineer explained. “It means repeat- ing procedures, delaying diagnoses, or compromising workflow in the lab.” Smiths Interconnect’s D Series is designed to withstand up to 20 autoclave cycles. Utilizing a high strength poly- mer for both the plug and receptacle, the D Series is selectively loaded with up to 82 hyperboloid contacts, allowing conformity to most device requirements.

Hyperboloid Technology

In applications like this, contact geometry becomes as important as materials and sealing. Technologies used by Smiths Interconnect, such as its hyperboloid contact design, distribute contact force across multiple points rather than relying on a single beam or spring. This multi-point engagement helps maintain consistent electrical performance even after repeated sterilization cycles. “In healthcare, reliability has to be repeatable,” a design engineer noted. “A connector that survives one sterilization cycle isn’t enough, it has to survive multiple cycles without changing behavior.” In addition to sterilization and reliability, many medical devices also face extreme space constraints, particularly in portable diagnostic equipment, wearable systems, and minimally invasive tools. In these applications, con- nectors must deliver reliable signal performance while occupying as little physical space as possible.

Omnetics, Nano-D Series

One approach to this challenge can be seen in miniature, high-density connector solutions such as the Nano-D and Nano Circular families from Omnetics, which are commonly selected for medical and life-science devices where size, weight, and precision are critical. These designs allow engineers to integrate multiple signal paths within compact assemblies while maintaining the mechanical stability required for repeated use and handling. “In medical designs, miniaturization can’t come at the expense of reliability,” one product engineer noted. “The connector still has to perform the same way every time.”

modules, flight control systems, and sensor payloads where multiple signal paths must be routed through limited space. One example of this design approach can be seen in miniature connector solutions developed specifically for high-reliability aerospace and defense applications. Omnetics has addressed these requirements through its Nano-D and Nano Circular connector families, which are designed to provide high-density connectivity in ultra-compact, lightweight form factors. Nano-D connectors, based on a scaled-down D-style interface, enable engineers to pack a high number of contacts into space-constrained avionics assemblies, while Nano Circular connectors offer a cylindrical alter - native suited for applications where rotational alignment and vibration resistance are key considerations. Both formats are commonly selected in aerospace systems where maintaining electrical performance under vibra- tion must coexist with aggressive SWaP targets.

Aerospace systems: reliability where size, weight, and vibration converge Aerospace applications present a distinct harsh-envi- ronment challenge where size, weight, and reliability are inseparable design constraints. Avionics, satellites, unmanned aerial systems (UAS), and spaceborne instru- mentation operate under continuous vibration, extreme temperature variation, and strict SWaP (size, weight, and power) limitations. In these environments, every gram and every cubic millimeter matters, yet reliability cannot be compromised. Unlike ground-based systems, aerospace platforms must maintain signal integrity and mechanical stability while exposed to sustained vibration during launch or flight, rapid pressure, and temperature changes. There are also limited opportunities for maintenance once deployed. Connectors that are oversized or overly complex can introduce unnecessary weight and integra- tion challenges, while connectors that lack mechanical robustness risk intermittent failures that are difficult or impossible to service after deployment. “In aerospace, you don’t get a second chance to reseat a connector,” one avionics engineer explained. “Once it’s in the air or in orbit, it has to work.” To meet these demands, aerospace connectors are often required to deliver high contact density in extremely compact for- mats while maintaining secure mating under vibration and shock. This balance is particularly critical in avionics

Omnetics Nano Circular connectors

Ease of integration is also a factor. Aerospace manufac- turing and assembly often require precise, repeatable mating without excessive force or complex handling, especially when connectors are installed in densely populated assemblies or hard-to-access locations. “The challenge isn’t just making the connector survive vibration,” one systems engineer noted. “It’s doing that while keeping the connector small enough that it doesn’t drive the rest of the design.” By addressing vibration tolerance, contact density, and mechanical stability within miniature designs, aero- space-focused connectors demonstrate how harsh-en- vironment reliability can be achieved without sacrificing size or weight. As aerospace systems continue to push toward greater functionality in smaller platforms, con- nector solutions that successfully balance these com- peting demands become essential elements of overall system reliability. Engineering responses: designing for reality To survive these conditions, harsh-environment con- nectors rely on more than rugged housings. Secure locking mechanisms prevent accidental unmating under vibration and shock. Advanced sealing technologies

protect against moisture and chemical ingress. Careful material selection preserves electrical performance and mechanical strength over long service lives. Usability matters as well. “If a connector requires per- fect conditions to mate,” a defense systems engineer observed, “it’s not designed for the real world.” Field maintenance, gloved operation, and rapid deployment all influence connector performance in ways that rarely show up on datasheets. Rethinking the role of the connector Many teams only recognize the true role of the connec- tor after a failure occurs. In harsh environments, con- nectors are often among the most mechanically stressed components in the system, yet they are frequently specified late in the design process. “We validated elec - tronics and software for months,” one project engineer admitted, “and the issue that brought the system down was a connector we assumed was ‘good enough.’” Connectors in harsh environments do far more than pass signals. They are expected to tolerate vibration and shock, resist environmental ingress, and support maintenance and reconfiguration, often under time pressure and far from controlled conditions. When these demands are underestimated, the connector becomes the weakest link in an otherwise robust system. The overlooked variable: how the connector is selected Even the most capable connector can fail if it’s misap- plied. Many failures trace back not to poor design, but to incomplete context during selection. Environmental ratings alone rarely tell the full story. How often will the connector be mated and unmated? Will operators be wearing gloves? Is vibration continu- ous or impulsive? Is chemical exposure occasional or routine? “Most connector failures don’t happen because the part was wrong,” an experienced engineer noted. “They happen because someone didn’t ask the second or third question.” At this point, connector selection shifts from a procure- ment task to a risk-management decision. Reliability is a team effort Successful harsh-environment systems are rarely the result of component choice alone. They emerge from collaboration—between design engineers, buyers, and

technical specialists who understand not just specifi - cations, but deployment, maintenance, and lifecycle realities. In applications where downtime, rework, or failure carry real cost, the role of the supply chain partner extends beyond fulfillment. Organizations that pair technical expertise with a high-touch service model, ensure decisions are informed, responsive, and accountable— qualities that become critical when systems move from design into deployment. “When the system is deployed, nobody remembers who selected the connector,” an operations engineer observed. “They only remember whether it worked.” Projects that incorporate early technical guidance, cross-manufacturer perspective, and long-term sup- port reduce surprises in the field and make reliability repeatable—not accidental. Designing for what actually happens Modern harsh-environment applications demand high- speed data transmission, optimized size and weight, and fast, secure mating for field service. As commercial interfaces migrate into industrial and defense systems, the challenge becomes clear: convenience and perfor- mance must be matched with durability and mechan- ical security. The most advanced technology is only as reliable as its most vulnerable connection. The connector as a mission-critical decision In harsh environments, connectors are no longer com- modity parts. They are mission-critical decisions that directly affect safety, uptime, and system performance. Whether deployed in aerospace, defense, medical, industrial, or energy applications, a single connector failure can outweigh the cost and complexity of every other component in the system. Engineers and buyers who recognize this early—who design for vibration, moisture, temperature, and real-world handling—avoid the painful lessons learned by many before them. “You don’t notice a good connector,” a veteran engineer concluded. “You only notice the bad ones. And by then, it’s already too late.” Ultimately, connectors designed to survive harsh envi- ronments are not defined by a single specification, but by how well they endure the realities of use over time. Visit Kensington Electronics Inc. to learn more.

Resiliency is the defining mantra of rugged and reliable interconnect solutions that must withstand environ- mental extremes and performance stress under the most demanding conditions. Achieving this requires blending data-driven science—mechanical engineer- ing, signal integrity and material science—with the art of intuitive judgment and foresight that experienced engineers apply when designing for the real world. Reliability is not merely the absence of failure; it de - mands the mastery of the margins and the anticipation of the unknown. To accomplish this, rigorous testing must be paired with astute analysis of scientific data and models. Then, alignment with creative problem solving is key to interpreting both the hard facts and gray areas of mission-critical design. The science of connector design is rooted in intelligent tools that predict measurable outcomes. Meanwhile, the art of developing connectors is guided by instinct honed over decades of designing products for en- vironments where “good enough” results in a point of failure. For most of the mission-critical solutions developed by the Aerospace and Defense Solutions (ADS) division at Molex, an overarching focus on science provides a crucial safety margin, while the commitment to art drives ongoing innovation.

The Art and Science of Failure Prevention In the high-stakes worlds of aerospace and defense, where ruggedness and reliability reign, it is imperative to blend objective, data-driven science with engineering intuition and innovation

George Dubniczki Chief Technology Officer and VP of Engineering at the Aerospace and Defense Division

Molex

Nearly all engineers polled among the 1,000 participants in the 2025 State of Design Engineering in Aerospace and Defense report from Molex cited AI-assisted design expertise as crucial to their company’s future success.

Understanding the physics of failure Connector failure is rarely a single event; it’s a culmi - nation of mechanical, electrical, chemical, or thermal degradation. The Physics of Failure (PoF) is a scientific approach that investigates why a component failed by analyzing physical mechanisms like stress, fatigue, or corrosion. Forensic analysis is particularly critical when dealing with microscopic threats like the volatile nature of material outgassing in the vacuum of space. The application of science leads to chemical formulas designed to prevent major issues, along with specialized plating and finishes that maintain conductivity without compromising the structural integrity of the housing over a two-decade mission lifespan. Bridging the gap from why to how requires digital stress tests, including Finite Element Analysis (FEA) and Compu- tational Fluid Dynamics (CFD). These simulations apply mathematical equations to see how elements react to external forces. For instance, if a connector is vibrated at high G-forces, FEA shows exactly where metal might fatigue or a solder joint might crack. Armed with this insight, engineers can remove excess material or reinforce critical zones, achieving an opti- mal balance of low weight and high ruggedness. CFD, another digital forensics tool, simulates how fluids or air move to carry heat away from critical components. In high-speed systems, where heat is the enemy of reli- ability, CFD helps engineers identify stagnant air pockets where heat could trigger system failure. “ Connector failure is rarely a single event; it’s a culmination of mechanical, electrical, chemical, or thermal degradation

This digital proving ground is essential for envisioning the unseen stressors of deep space or tactical battle- fields where repair is not an option. In these cases, simulation is the bridge that enables engineers to visu- alize how products will behave over decades of service. Careful evaluation of performance and design tradeoffs leads to improvements in electromagnetic interference (EMI) shielding and signal integrity. Sophisticated routing strategies help reduce crosstalk and signal degradation over long distances, maintaining signal fidelity through advanced shielding.

AirBorn verSI Series high-density connectors perform reliably under extreme conditions, including rigorous shock and vibration testing, making them ideally suited for mission- critical aerospace and defense applications. The Molex ADS engineering team has long embraced a simulation-first philosophy, with emphasis on predictive engineering and material science. This approach proved instrumental in development of AirBorn verSI Series connectors. Since a well-engineered contact system is key to dependability, engineers designed the product with up to four points of contact. This redundant system continues to operate even if one contact experiences a momentary interruption due to excessive vibration or debris. Extensive testing measured electrical degradation using the EIA-364-09 standard, with demonstrated contact resistance after 2,500 cycles. Some customers even reported flawless operation beyond 20,000 mating cycles, representing the ideal mix of longevity and signal integrity. Creative foresight: digital twins and agentic AI While PoF offers a forensic blueprint of what could go wrong, the complexity of thermal expansion and high vibration requires help in forecasting when a failure might occur. For example, if a connector is on a rocket, predictive algorithms calculate the impact of specific vibrations and temperature swings on the molecular integrity of the connector’s materials. This lets engineers choose materials that will not release gases in a vacuum,

The art of customer-driven innovation If the digital twin is the map and Agentic AI is the naviga- tor for innovative connector designs, then the customer is the ultimate source of the unknown. Customer-driven innovation is about understanding the collective gray areas that can define mission success or failure—factors that only appear when modules are pushed beyond their limits.

which is crucial for space applications. Contact physics also address the balance of gold-plating thickness for conductivity against the demands of fretting corrosion. In the pursuit of mission-critical reliability, engineers go beyond forecasting the length of time before something breaks. They also rely on data-driven models and digital twins to design out all weaknesses before a prototype is even built. Instead of building 10 physical versions of a high-density backplane, for instance, engineers run thousands of iterations on one digital twin to identify geometric bottlenecks or signal interference. Once deployed, digital twins become real-world health monitors. They ingest aircraft sensor data to calculate how much fatigue specific components endure based on actual flight maneuvers. This real-time information is used to update predictions for interconnector lifes- pans. Thanks to ongoing advancements in AI, machine learning, and augmented reality/virtual reality (AR/VR), digital twins will continue to evolve. According to the 2025 State of Design Engineering in Aerospace and Defense report from Molex, which surveyed more than 1,000 participants with direct en- gineering responsibility, AI-assisted design expertise is critical to future success. Nearly all engineers (98%) cited benefits, including increased creativity (60%), reduced costs (53%), improved testing scenarios (45%), strength- ened security (44%), and support for alternative parts and material selection (37%). Interest in Agentic AI is accelerating because it goes beyond standard AI chatbots to identify the best path to prevent failure. These proactive agents can execute the necessary steps to maintain a mission, such as autonomously adjusting workloads or thermal man - agement profiles, when environmental variables veer into unknown territory.

SInergy modular high-speed hybrid connectors support complex high-performance systems, providing up to 256 Gb/s per lane in a modular form factor, ensuring reliability in industrial, and aerospace and defense applications. AirBorn SInergy mini-modular hybrid connectors emerged after customers voiced a need for modular solutions that combined signal, power or RF into a single interface. Merging high-speed performance with military-grade resilience, SInergy delivers up to 25 Gb/s per lane. This makes SInergy ideal for applications such as military heads-up display helmets where real estate is at a premium. Beyond electrical performance, the "art" of innovative designs is deeply rooted in human-centric engineering. In a high-stress tactical environment, a connector’s success often hinges on usability. Engineers must in- tuitively accommodate "blind-mate" scenarios where a technician may be working in zero-visibility conditions

or wearing thick, cold-weather gloves. The goal: antici - pate the physical limitations of the human operator to ensure a secure connection long before the system is powered on. The future of next-generation systems depends on these modular solutions and open standards to enable economical technology scaling. Trusted architectures empower engineers to focus on functionality rather than compatibility. The state-of-design engineering survey from Molex revealed that 94% of respondents maintain a positive outlook on the value of open stan - dards, even though the majority (57%) are still in the early stages of investigating or implementing open system architectures. Mastering the margins: MOSA, SOSA, VITA and the power of synergy Mastering the margins of the unknown also requires industry-wide collaboration forged through active lead- ership within the committees working on emerging stan - dards, including Modular Open Systems Architectures (MOSA), Sensor Open Systems Architectures (SOSA), and VMEbus International Trade Association (VITA). Molex and AirBorn engineers have been active in helping author standards that define modern interoperability. This collaborative synergy serves as a force multiplier for customers. Not only is the integration process de-risked for system architects, but customers can also bypass the trial-and-error phase of development. As a result, they can move quickly from a conceptual MOSA architecture to a deployable, high-performance solution and a faster path to mission readiness.

tion for the rest of the ecosystem—including the new 3U VPX processing cards featuring AMD Versal Adaptive SoCs from BittWare, a Molex company. As the industry pushes into harsher frontiers—deeper space, faster data rates, and more extreme tempera- tures—there will be a relentless need to redefine the threshold of ruggedness and reliability. It is the mastery of the margins, fueled by the science of data-driven insights and the art of foresight and creative problem solving, that ensure operational continuity when there is no room for error.

Visit Molex to learn more.

AirBorn 3U VPX Power Supply delivers up to 1,000 watts of power in a compact form factor that’s one-third the size and weight of the award-winning 6U model, ideal for space-con- strained aerospace and defense applications. At the MOSA Industry & Government Summit in August 2025, Molex introduced the AirBorn SOSA-aligned 3U VPX Power Supply , which delivers 1,000 watts of efficien - cy in a footprint 70% smaller than previous generations. This physical innovation provides the essential founda-

THE RIGHT INTERCONNECTS FOR YOUR APPLICATIONS

Rugged Interconnect Solutions for Heavy Equipment in Harsh Environments BUILT TO LAST:

EDAC Group of Companies Marco Lamanna Senior Digital Marketing Specialist

Heavy-duty vehicles and industrial machinery operate in environments that actively degrade electrical systems. In construction, agriculture, mining, and rail applications, equipment en- dures dynamic loading, weather extremes, and contaminants. Unlike stationary electronics, interconnect systems in off-highway vehicles must maintain signal integrity and power de- livery while experiencing constant mechanical stress and thermal cycling. These interconnects often sit at the ends of long harnesses routed through moving joints, exposed frames, and frequent service points, making connectors among the most failure-prone elements of the electrical system. Reliability in these applications is not just con - venient, it is a critical safety and economic re- quirement. A single connector failure can cause open circuits, signal loss, or intermittent faults that mimic software errors, leading to costly downtime and difficult diagnostics. Designing for these environments requires a systems-lev- el approach that accounts for environmental stressors, potential failure modes, and rigorous validation standards defined by organizations such as SAE, ISO, and IEC.

metal to oxidation. The resulting oxide buildup increases resistance and causes intermittent signal failure. Tin-plated contacts are particularly susceptible under vibration. • Water ingress and insulation breakdown. Moisture entry via capillary action or seal breach can lead to short circuits and electrochemical migration. • Seal compression set. Elastomeric seals may lose their ability to rebound at elevated temperatures, reducing sealing pressure and allowing contamination ingress. • Contact back-out. Inadequate retention mechanisms may allow contacts to dislodge under mechanical shock. • Cable fatigue and strain failure. Harnesses routed across articulated joints or tight bend radii can experience conductor fatigue at the connector exit, leading to intermittent opens or complete breakage. • EMI interference. In electronically noisy environments, unshielded or poorly grounded connectors can couple electromagnetic interference into sensitive control circuits.

Micro-D connector, compact design signal interface with back- shells Environmental stressors Engineers must characterize specific operating conditions to select appropriate ruggedized interconnects. Primary stressors in heavy equipment applications include: • Vibration and mechanical shock. Heavy-duty vehicles generate and encounter vibration ranging from steady shaking to high-energy impacts caused by rough terrain. Shocks and impacts can compromise mechanical retention and contact stability. • Dust and mud ingress. Fine particles act as abrasives on contact surfaces and absorb moisture, creating conductive contamination paths. • Washdown and pressure cleaning. Equipment is frequently exposed to high-pressure, high-temperature washdowns. IP69K conditions can reach approximately 80-100 bar water pressure at elevated temperatures, stressing seals and insulation systems. • Chemical exposure. Connectors encounter engine oils, transmission fluids, hydraulic fluids, diesel fuel, and fertilizers. These fluids can attack connector housing materials and elastomers if chemical compatibility is not verified. • Temperature extremes. Components face −40 °C cold starts and elevated under-hood temperatures exceeding +125 °C, producing expansion and contraction that challenge seal integrity. • Corrosion. Coastal environments and road salts introduce saline solutions that accelerate oxidation and galvanic corrosion, particularly on chassis-mounted components. Common connector failure modes Understanding how connectors fail in the field is essential for preventative design. • Fretting Corrosion. Micro-motion between mated contacts rubs away the plating layer, exposing base

D-subminiature connector with backshell

Engineering design practices To mitigate these risks, system architects should follow robust design practices rooted in materials science and mechanical engineering. • Sealing Strategies. Robust designs use layered protection, combining an interface gasket, individual wire seals at the cable entry, and a strain-relieved or clamped backshell. For exterior locations, components capable of meeting IP67 or IP69K requirements are commonly specified. • Plating Selection. The choice between gold and tin is critical. Tin is cost-effective but relies on high contact force to break through oxides, is prone to fretting in high-vibration areas, and may present reliability risks such as tin whisker growth over time. Gold, supported by a nickel underplate, provides stable low-resistance

contact and improved performance in vibration- prone or low-signal circuits. • Termination methods. Crimping is generally superior to soldering for mobile equipment. A proper crimp forms a gas-tight joint that resists oxidation and vibration, whereas soldered joints create rigid stress points susceptible to fatigue cracking. • Strain relief and overmolding. Strain relief features, backshells, or overmolded cable assemblies distribute bending loads and protect terminations from mechanical stress. • Mechanical retention. Secondary locking features and positive latching mechanisms prevent contact movement and accidental disengagement. • EMI shielding. For signal lines, 360° shield termination maintains continuous grounding and reduces susceptibility to noise. • Current derating. In sealed systems, limited airflow reduces cooling. Connectors should be selected using conservative derating practices to prevent thermal overload. Connector types commonly used in heavy equipment Different interconnect styles address varying elec- trical and mechanical requirements within the same machine. High-density signal interfaces may use compact rectangular formats such as Micro-D or D-Subminiature connectors. Circular connectors are frequently selected for sealed I/O and sensor interfaces where secure coupling and environmental protection are required. Inline wire-to-wire connectors provide serviceable harness breakpoints, while ring terminals remain common for high-current power and grounding connections to studs or bus bars. When packaging, sealing, or retention needs exceed standard solutions, semi-custom or fully customized designs are often developed to meet specific environmental and mechanical requirements.

Sealed metric circular connector with threaded coupling

Validation and testing Validation ensures interconnects can survive the defined lifecycle. Relevant standards include: • Ingress protection (IEC 60529 / ISO 20653). IEC 60529 defines standard IP ratings such as IP67 for immersion protection. ISO 20653 is specific to road vehicles and includes IP69K testing for high- pressure washdown. “ Customized designs are often developed to meet specific environmental and mechanical requirements.

• Vibration and shock (IEC 60068 / SAE J1455). IEC 60068-2-6 and IEC 60068-2-27 simulate mechanical stresses to identify structural weaknesses. SAE J1455 provides environmental practices and vibration testing for heavy-duty vehicle applications. • Corrosion resistance (ASTM B117 / ISO 9227). Salt spray testing provides comparative data on plating and coating durability in corrosive environments. • Connector performance (EIA-364). Covers contact resistance, mating force, durability, and thermal shock testing.

• Define the environmental zone of each connector location • Verify the required ingress rating • Select appropriate contact plating • Review derating curves for temperature and current • Include strain relief or overmolding • Confirm fluid and chemical compatibility • Specify shielding for sensitive signals • Validate using recognized IEC, ISO, SAE, ASTM, and EIA methods Ruggedizing interconnect systems for heavy equipment requires more than selecting a robust-looking housing. It demands understanding how vibration, contamination, temperature, and material behavior interact over time. By applying disciplined design practices and validating designs to established industrial and heavy-vehicle standards, engineers can develop interconnect systems that withstand field conditions and deliver consistent long-term performance. Visit EDAC Group and brands to learn more.

Inline wire-to-wire dual latch harness connector

Ring terminals for high-current power/ground connections

Overmolded or custom cable assembly with integrated strain relief Practical design checklist Design engineers can use the following checklist during component selection and system review:

Precision agriculture, also referred to as smart farming, has reshaped farming operations from how crops are planted to how they’re monitored and harvested. Once reserved for early adopters or large-scale opera- tions, precision agriculture is now an expectation across various regions and for farms of all sizes. Pressure to reduce labor, decrease chemical inputs, conserve water, and operate in tighter windows puts the focus on smart farming as a multi-faceted solution. Farmers are turning to new technologies to make smarter deci - sions that boost yields, reduce risk, and ensure operations run efficient - ly. With global food demands and environmental pressures, the need for precise, accurate, and intelligent farming has never been greater. Because of this, data intelligence be - comes critical to operational success. In the field, sensors, cameras, and antennas are tasked with monitoring and collecting data on soil conditions, crop health, weather patterns, and equipment performance. Utilizing this data, farmers can shift their focus to variability at both the field and plant level rather than relying on tradi- tional, more manual, labor-intensive strategies for the same information.

The Engine Behind Precision Agriculture ROBUST AND RELIABLE CONNECTIVITY:

Jennifer Love Product Manager TE Connectivity

“ Data connectivity solutions are the backbone of precision agriculture and must be robust, rugged, and reliable

DT high speed sealed connector

What’s the engine driving data col- lection? The answer is connectivity. Data connectivity solutions are the backbone of precision agriculture and must be robust, rugged, and reliable. In the past, many OEMs were using

automotive connectors in their equipment because that’s all that was available. However, they quickly learned that those did not withstand the harsh condi- tions of the farm field. Current connectivity solutions can tolerate exposure to the elements, including relentless vibration, extreme temperatures, heavy moisture, and dust-laden conditions, allowing systems to still function consistently and accurately. Driving decisions with data With smart farming technologies, farmers can make more intelligent decisions using systems that moni- tor soil moisture, temperature, and weather and use data-driven strategies to build operations that can better withstand changing conditions. One of the most powerful benefits of precision agriculture is its ability to address variability. Differences in soil composition, nutrient availability, moisture, and pest pressure can ex- ist closely together. Traditional farming methods often treat entire fields or sections of a field as a single unit, but now data enables technologies such as variable-rate seeding, targeted spraying, and yield mapping allow farmers to treat only the areas needed. Studies have shown that utilizing data-driven systems can reduce water, fertilizer, and chemical inputs by as much as 15-30% while maintaining or improving yield. This approach strengthens long-term soil health and resource efficiency, improves productivity, and supports sustainability.

blurry due to exposure to the elements. TE worked with the customer to develop a fully sealed connector system that allows the camera to function properly even when exposed to elements such as water, pesticide, and mud. The result was clear images that enabled more informed decision making. Predicting equipment failures before they happen Agriculture vehicles are expensive, which makes their productivity essential to ensure a return on investment. Owners could potentially lose thousands of dollars a day if machinery is out of service. On the flip side, operators can increase their returns if the life of those vehicles can be improved or extended. Advancements in predictive maintenance technology have proven beneficial in the farming industry. Sensors embedded on equipment continuously monitor equipment health, tracking factors such as vibration, temperature, and performance, and looking for patterns that could signal potential issues before they result in failure. Employing a predictive maintenance strategy helps farmers avoid unexpected breakdowns during critical planting or harvesting windows when downtime can have impacts on yield and profitability. Rather than having to address equipment failures after they occur, farmers can plan service proactively and schedule maintenance during off-peak periods, which reduces

Cameras mounted on sprayers are an example of how precision agriculture helps farmers monitor their fields. These cameras identify weeds at the nozzle level and trigger targeted herbicide applications instead of blan- ket spraying. These cameras depend on a reliable data connectivity system to capture and transmit photos. For example, one TE customer was utilizing a sprayer for more than 30 cameras, but the camera images were

operational risk and helps to extend the overall lifespan of their machinery. Remote monitoring also reduces the need for direct human interaction with heavy machinery as well as exposure to hazardous chemicals and conditions. Op- erators can maintain oversight of their equipment from afar, increasing worker safety.

Overcoming barriers to greater adoption Despite its benefits, there are barriers to adoption of new farming technologies. Advanced equipment with smart technologies come at costs ranging from tens of thousands to half a million dollars or more, depending on farm size and application. Technical complexity is also a challenge, especially when integrating multiple systems or managing large volumes of data. Connectivity remains a hurdle. Many farms operate in rural areas with limited or inconsistent network infra - structure, which can make reliable data transmission difficult. From a workforce development standpoint, farmers are experts in their land and crops but may take time to learn these new technologies, especially in predominately rural areas.

Looking ahead: smart farming will become even smarter Over the next three to five years, precision agriculture is expected to become even more mainstream. As in- novations continue to advance, robust and reliable data connectivity will remain the engine behind consistent progress. Future-ready, customizable connectivity will drive productivity, support sustainability, and set the standard for precision farming performance. Intelligent, high-performance connectivity solutions engineered to perform in the most demanding agricultural environ- ments will ensure robust data transmission, system reliability, and design flexibility. Solutions are becoming more scalable, supporting both small and large oper- ations, and system integration is leading to a smarter, more connected, and more productive farming future. Visit TE Connectivity to learn more.

What Oilfield Engineers Need from Their Connectors (How Distributors Help Them Get There) BEYOND IP RATINGS:

Jim McNeil General Manager

TTI IP&E

Walk into a design review for an oilfield project and you will often hear, “Is it IP68?” But anyone who’s spent time in the field knows that is just the beginning. The real world is messier; connectors face temperatures that warp plastics, chemicals that eat seals, vibrations that shake contacts loose, and electrical interference that can turn vital data into noise. As distributors, we’re the ones who get the call when a “fully sealed” connector fails after six months in a sour gas environment, when a vibration-prone motor keeps losing signal, or when vital equipment puts your rig down because parts weren’t up to snuff. Our job is not to ship boxes, it is to help engineers avoid these headaches by matching their needs to the right solutions, with the documentation and spares to keep operations moving forward. From spec sheet to field reality: The questions that matter When a design engineer reaches out, the conversation quickly moves past catalog numbers to component specifics.

“ When a design engineer reaches out, the conversation quickly moves past catalog numbers to component specifics.

•

What’s the worst this connector will see? Is it temperature, chemicals, vibration, pressure, or all the above? Is this a one-time install, or will techs be completing multiple mating cycles, in the rain, or with an ROV 2,000 meters down?

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Is this part of critical operations?

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How challenging is redundancy (for the equipment or spare parts)? What’s the cost of downtime if equipment fails?

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