Custom Connectors | Electrical Connector Accessories

Custom Connector

Connector Customization Process

Requirements discussion → Drawing design and technical review → Mold development and prototype manufacturing → Sample assembly and performance testing → Design validation and optimization → Process finalization and preparation for mass production → Mass production and delivery → After-sales technical support and continuous improvement

Advantages

Technical Expertise
More than 10 years of experience in military-grade R&D, with hundreds of customized products successfully delivered.
In-House Manufacturing
Independent capabilities across tooling, CNC machining, and full mass production, with support for flexible small-batch production.
Quality Control System
Military-standard IQC, IPQC, and FQC inspection system with 100% traceability of key processes.
Efficient Delivery
One-to-one dedicated service, sample delivery in as fast as 30 days, and up to 15% reduction in mass production lead time.
Full Lifecycle Service
End-to-end support including product selection, cost optimization, and upgrade and iteration services.

We rely on years of experience in military and industrial connector development, offering full-range customized solutions from standard specifications to extreme operating conditions.

Customization of Structure and Specifications

Standards supported: Includes US military standards (MIL-38999), Russian standards, and fully custom non-standard designs (e.g., HW-76ZKNP3).
Contact matrix: Covers configurations from single-core to high-density arrays. Options include pitch (e.g., HSB series), contact types (crimp, solder, PCB direct), and support for mixed high-current and high-frequency transmission.
Mechanical interface: Housing dimensions, mounting methods (panel, cable, flange), and locking systems (bayonet, threaded, push-pull self-lock) fully customizable.

Electrical and Environmental Performance Customization

Electrical parameters such as insulation resistance, dielectric strength, and contact resistance can be tailored, covering low-frequency to high-speed and RF ranges (e.g., SMA/BMA series).
Designed for harsh environments, operating from -55℃ to +125℃+, with options for vibration resistance, shock resistance, and full protection against moisture, mold, and salt spray.
Mechanical lifespan can be set from 1000 to 10000+ mating cycles for high-frequency and high-reliability applications.

Material and Process Customization

Housing materials: Options include aluminum alloy, brass, stainless steel, and composite materials, with nickel, gold, cadmium plating, and passivation treatments for improved shielding and corrosion resistance.
Precision plating: Contact plating options include gold (e.g., 1.27μm), silver, and tin, selected to balance conductivity and cost.
Special processes: IP67/IP68 sealing protection, anti-misplug keying, EMI shielding, and flame-retardant material options are available for demanding environments.

Typical Applications

Electrical parameters such as insulation resistance, dielectric strength, and contact resistance can be customized, covering low frequency to high-speed and RF ranges (e.g., SMA/BMA series).
Designed for harsh environments, operating from -55℃ to +125℃+, with options for vibration resistance, shock resistance, and full protection against moisture, mold, and salt spray.
Mechanical lifespan can be set from 1,000 to 10,000+ mating cycles for high-frequency and high-reliability applications.
RF/microwave applications: Custom SMA and BMA coaxial connectors for low-loss high-frequency signal transmission.
High-density interconnect systems: High-density connectors such as HSB series and HW-KA68254DPV32MDTH designed for compact devices with multi-signal transmission needs.
Non-standard equipment: Custom RPJ30 connectors for special equipment interfaces with unique connection requirements.

Examples of Customized Connectors

HW-1-2L-25SSMRTN

Materials
Insulator	Glass-filled PPS, UL 94-V0
Contact	Copper alloy, 1.27 μm gold plated
Shell	Aluminum alloy, nickel plated
Attachment	Stainless steel
Electrical
Dielectric Withstanding Voltage	600 V @ sea level
Insulation Resistance	≥ 5000 MΩ @ 500 VDC
Rated Current	≤ 3 A
Contact Resistance	Initial: ≤ 10 mΩ
Magnetic Permeability	≤ 2 μ
Mechanical
Mating cycles	500 cycles
Shock	50 g
Vibration	20 g
Environmental
Operating Temperature	-55 °C to +150 °C

HW-76ZKNP3

Environmental	Operating Temperature	-55 °C to +165 °C
Dynamic	Sinusoidal Vibration	10 to 2000 Hz, 196 m/s²
	Random Vibration	0.4 g²/Hz PSD, 23.1 g RMS
	Mechanical Shock	735 m/s² , 11 ms
Electrical	Dielectric Withstanding Voltage	800V
	Insulation Resistance	≥ 5000 MΩ
	Contact Resistance	≤ 10 mΩ
	Rated Current	3 A
Mechanical	Mating cycles	500 cycles
Materials	Shell	Aluminum alloy, nickel plated
	Insulator	High-performance Engineering Plastics
	Contact	Copper alloy, Gold over Nickel plated

RPJ30 Series (Models: RPJ30-15ZK-15 / RPJ30-15TJ)

Mechanical	Sinusoidal Vibration	1 to 2500 Hz, 40 g peak
	Mechanical Shock	1500 g peak
	Linear Acceleration	100 g (1000 m/s²)
Environmental	Operating Temperature	-60 °C to +85 °C
	Storage Temperature	-60 °C to +70 °C
	Relative Humidity	Up to 98% RH @ 35 °C (Non-condensing)
	Special Environment Resistance	Resistant to specific harsh factors
	Multiple Acceleration	1500 m/s²
	Low Pressure	1.3 × 10⁻⁴ Pa
	Mating cycles	250 cycles
	Mean Time Between Failures	1000 h @ 90 °C or 9000 h (weighted per contact count)
Electrical	Contact Resistance	≤ 0.01 Ω
	Insulation Resistance	≥ 5000 MΩ
	Dielectric Withstanding Voltage	800 V
	Operating Current per Contact	≤ 1.0 A
	Maximum Current per Contact	≤ 2 A
	Maximum Operating Voltage	150 V
	Shelf Life	25 years

SMA Series & BMA Series

Material	Insulator	PEI
	Center Contact	Gold-plated copper alloy
	Outer Contact	Passivated Stainless Steel
Electrical	Characteristic Impedance	50 Ω
	Frequency Range	DC to 18 GHz
	Insulation Resistance	≥ 5000 MΩ
	Contact Resistance	Center Contact: ≤ 6.0 mΩ Outer Contact: ≤ 3.0 mΩ
	Dielectric Withstanding Voltage (DWV)	1000 V
	Voltage Standing Wave Ratio (VSWR)	1.2:1
Mechanical	Mating cycles	500 cycles
Environmental	Operating Temperature	-55 °C to +165 °C
Environmental	Interface Standard	MIL-STD-348A

HSB Series High Density Connector

Material	Insulator	30% Glass-filled LCP
	Contacts	0.65 mm Twist Pin
	Accessories	Stainless Steel
Electrical	Dielectric Withstanding Voltage (DWV)	800 VAC @ Sea Level
	Insulation Resistance	≥ 5000 MΩ
	Current Rating	≤ 3 A
	Contact Resistance	≤ 10.0 mΩ
Mechanical	Sine Vibration	10 to 2000 Hz, 196 m/s²
	Random Vibration	0.4 g²/Hz PSD, 23.1 g RMS
	Mechanical Shock	735 m/s², 11 ms
	Mating cycles	2000 cycles
Environmental	Operating Temperature	-55 °C to +125 °C