Key Takeaways

• Molex expands AirBorn SInergy connectors to include heavy-duty, high-power contacts, increasing power delivery capacity to 25.0A.
• The modular connectors offer flexibility with interchangeable bays for power, signal, and RF contacts, enhancing design capabilities for aerospace and defense applications.
• The design aims to streamline supply chains and reduce material complexity, addressing the growing power and data transfer requirements in advanced systems.

Innovative Expansion of AirBorn SInergy Connectors

Molex, a leader in electronics and connectivity, has announced an expansion of its AirBorn SInergy Modular High-Speed Hybrid Connectors, introducing robust, high-power contacts capable of delivering up to 25.0A. This development offers a substantial 12.5x increase in power capacity, designed for compact systems operating in demanding environments where reliability is critical.

According to Billy Rhea, group product director for Aerospace and Defense Solutions at Molex, this enhancement meets the escalating demands of next-generation aerospace and defense systems, facilitating quicker design processes. The SInergy platform enables customers to combine high-power, high-speed data, and RF contacts into a single connectivity solution.

With the new AirBorn SInergy power modules, engineers can effectively address the needs of power-intensive applications like aircraft launch systems, radar, avionics, satellites, and combat vehicles. The connectors support high-density signal contacts with data rates of up to 25Gbps and RF contacts at frequencies reaching 40 GHz. This makes SInergy connectors ideal for challenging designs with space constraints.

The AirBorn SInergy system is distinguished by its configuration flexibility. Up to five interchangeable bays allow engineers to customize contact types, seamlessly integrating signal, power, and RF modules to meet specific requirements. This flexibility stands in stark contrast to traditional hybrid solutions that offer fixed layouts. The compact size of the one-bay connectors—approximately the size of a quarter—and various mounting options ensure secure mechanical alignment.

In addition to performance enhancements, the SInergy connectors simplify integration and improve supply chain efficiency. Historically, engineers have had to source multiple connectors from various vendors, complicating the design process. The SInergy connectors integrate various functions, reducing the bill of materials (BOM) and easing supply chain complexities, which accelerates time to market.

The SInergy portfolio is built on a legacy of innovation, reflecting the robust design traits of the MIL-DTL-83513 Micro-D and MIL-DTL-32139 Nano-D Connectors. The new modules are engineered to withstand extreme environmental conditions, satisfying MIL-DTL-83513 specifications for durability. The newly developed power contacts comply with the MIL-DTL-39029 standard for crimping and are engineered for a temperature rise baseline of 30°C over ambient, making them suitable for high-demand space applications with limited heat dissipation.

Research indicates that addressing increasing power needs is a top priority for designers in the aerospace and defense sector, with Molex’s report finding that 52% of surveyed engineers identified this as their primary concern. The survey also highlighted trends in power distribution and onboard management, high-speed data transmission, electronic defense, and advanced sensing technology.

The expansion of the AirBorn SInergy family reflects Molex’s commitment to closely collaborating with customers to fulfill precise specifications and preferences. This modular solution meets the growing needs of aerospace and defense OEMs, prime contractors, and Tier 1 suppliers, ensuring it reflects both current technological demands and future innovations.

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