In modern military, aviation, aerospace, marine, and defense systems, the equipment environment is complex—high temperature, low temperature, vibration, shock, humidity, salt fog, sea corrosion, electromagnetic interference (EMI), and other factors may pose challenges to electrical connections. Therefore, a connection system with extremely high reliability, stable performance, and the ability to withstand extreme environmental tests has become a key factor in determining whether the whole machine system can operate safely and stably for a long time. As a global leading supplier of interconnect solutions, TE Connectivity's Aerospace, Defense & Marine series cables, connectors, and sub-assemblies have been widely used in military aircraft, ground vehicles, naval ships, drones, satellites, missile systems, and other critical platforms. This article will discuss the electrical reliability of TE's military cable components in extreme environments, and provide reference suggestions for selection compatibility and alternative solutions for engineering design, procurement, and application.
One, characteristics and advantages of TE military cable assembly
• Comprehensive coverage of various military/aerospace applications: TE's Defense & Military product line covers a wide range of fields from ground vehicles, military aircraft, naval vessels, to space platforms, unmanned aerial vehicles, missile defense systems, and soldier-worn systems.
• High Reliability Design and Material Specifications: TE offers cables, connectors, backshells, optical fibers, and hybrid power/signaling systems, all of which are designed according to military/aerospace-grade standards (such as MIL-SPEC, VG standards, ESA/ESA-certified, SOSA/VITA, etc.) to ensure stable performance under harsh conditions.
Optimize space, weight, and power (SWaP): As modern platforms pursue lightweight, high-density, and high-bandwidth, miniaturized connector and cable designs have become a trend. TE offers a variety of products that meet SWaP optimization requirements while supporting high-frequency data transmission, strong anti-interference (EMI/RFI), and high-temperature and high-vibration environments.
High-speed and data integrity: Faced with an increasing number of systems based on data communication, images, videos, radar, and communication links, TE's fiber-optic and high-frequency connection solutions (fiber-optic / RF / high-speed backplane / multi-core hybrid) provide stable, high-bandwidth, and anti-interference connections for these systems.
Moduleization and System-level Integration Capability: TE not only provides single connectors and cables but also offers sub-assemblies, harnesses, mixed power/signaling systems, and even customized services for customers to support integrated connection solutions for complex systems.
Therefore, when facing extreme environments and high reliability requirements, TE military cable assemblies, with their mature design, rigorous testing, and extensive application foundation, have become the preferred connection solutions for many defense and aerospace systems.
Two, selection and compatibility/alternative solution reference and suggestions
In the process of project design or procurement, in order to ensure that the connection solution is suitable for system requirements and takes into account cost, substitutability, and ease of maintenance/maintenance, it is recommended to refer to the following aspects:
Environmental and Application Scenario Positioning
Firstly, clarify the environment where the harness/connection will be installed and used - whether there are conditions such as high vibration, high/low temperature, seawater corrosion, salt spray, humidity, impact, radiation, electromagnetic interference (EMI/EMP), etc. For extreme environments such as navy, ships, submarines, ground vehicles, battlefield personnel systems, aerospace/satellites, it is recommended to choose TE's high-reliability military/aerospace-grade products (for example, hermetic connectors, waterproof backshells, coating products tested for salt spray/corrosion, anti-EMI/RFI fiber optics, or shielded cables).
• Data rate and signal integrity requirements
If the system involves high-speed data communication, radar, image transmission, sensor networks, communication links, etc., it should prioritize TE's optical fiber solutions, RF / high-frequency connectors, mixed signal and power connections, and backplane interconnection systems that comply with VITA / SOSA / VPX and other standards. For traditional copper cables and connectors, also confirm whether their impedance matching, shielding, grounding, and anti-interference capabilities meet the requirements.
Modular design and system integration / post-extension requirements
For designs that require future upgrades, maintenance, module replacement, or system expansion, it is recommended to adopt TE's standard modular connection solutions (such as modular backplanes, replaceable modules, fiber modules, multi-core hybrid modules, etc.) to simplify maintenance, reduce inventory, and ensure diverse compatibility. TE offers a variety of standardized products (connectors, backshells, harnesses, fiber/copper, power & signal hybrids, etc.) for easy system integration and supply chain management.
Alternative and localization considerations (if there are procurement/supply chain constraints)
If due to cost, supply chain, delivery cycle, or policy requirements, domestic alternative solutions are desired, it is recommended to first divide them according to functions (high frequency / fiber / power / hybrid / protection level / corrosion resistance / temperature resistance / vibration resistance) and then compare the technical capabilities of domestic manufacturers. For example, evaluate domestic suppliers by comparing their products with TE's hermetic connectors / high-density, multi-core / fiber / hybrid / backplane / modular system functions. If the domestic solutions cannot fully meet the TE level temporarily, it can be considered to use them in a mixed manner - using TE for critical, harsh environmental, or high-reliability parts, and using domestic solutions for auxiliary or non-critical subsystems to balance cost and performance, compliance, and reliability.
In the selection of alternative solutions, it is recommended to carefully evaluate long-term reliability, compatibility (especially EMI/signaling integrity), ease of maintenance, and supply chain stability to avoid long-term system performance or maintenance cost issues due to initial cost savings.
As a globally leading provider of interconnect solutions, TE Connectivity's Aerospace, Defense & Marine series of military cable assemblies, with its high reliability, resistance to extreme environments, support for high data rates, high-density modular design, and system-level integration capabilities, has become the preferred connection solution for numerous defense, aviation, aerospace, marine, and ground military platforms. By selecting appropriate models, considering system environments and functional requirements, and combining domestic alternative solutions or hybrid solutions when necessary, one can balance cost, supply chain, and ease of maintenance while ensuring performance and reliability.
We continue to focus on and promote the research and development of domestic substitution solutions for this brand's connector and cable assembly components, as well as the development of market application solutions. If you are interested in the domestic substitution solutions of this brand or related products, have procurement needs, or are paying attention to this direction, please contact Manager Zhang.
18665383950, same number on WeChat). We hope to have in-depth communication and cooperation with more customers and industry partners.
