CABLE ASSEMBLIES

Amphenol Military & Aerospace Cable Assemblies

AMPHENOL CABLE MANUFACTURING

Amphenol Military & Aerospace Operations (AMAO) has the capabilities to meet a diverse range of cable and harness
assembly needs within the Military and Aerospace markets. We have over 550,000 sq. ft. of cable manufacturing space and
multiple locations in North America, Europe, and Asia to design, manufacture, and install harsh environment cable assemblies.
Our engineers have over 40 years of experience designing cables and harnesses to a wide variety of requirements. Amphenol’s
intra-company partnerships give us access to the largest interconnect product portfolio in the Military and Aerospace markets to
design and build anything from simple point-to-point cables and pigtails to complex multi-branch harnesses. AMAO
offers the broadest range of harness technologies covering standard and aluminum wires, high-speed, fiber, high
temperature, IP67 environment, RF and Microwave, semi-rigid, and flex PCB.

Harness Design Capabilities: Production Capabilities Include:

Electrical • Primary wire extrusions/jacketing for high end applications
• 3D design and routing • Experienced IPC/WHMA-A-620 certified workforce
(CAD, including CATIA V5 Software) • Automated twisters, strippers, cutters, crimpers
• Formboard for 2D definition Electrical wiring • Crimp capabilities for 777MCM to 26AWG wire
• Electrical Netlist • Custom overmold presses with in-house production tooling
• Design per EWIS best practices for Aerospace • Twisted shielded pair and quadrax cable assemblies
• Full testing capabilities for DWV, IR, continuity, etc.
Serial Design • Meet RTCA DO160 and MIL-STD-810
• Obsolescence management qualification standards
• Equipment manufacturing engineering • Five clean rooms (class 100,000) in North America,
Europe, and Asia

Overmolding: Automation and Quality Control:

• Amphenol excels in overmolding cable technology, • Laser and Ink Jet Marking
perfect for ruggedized power applications • Label and sleeve printing
• Custom overmold solutions utilize either low or • Komax: Mark, Cut, Strip, Twist, Crimp, Pull, X-Ray
high-pressure manufacturing methods, and include (Down to 32 AWG)
various environmental materials • AMP K-Press (Micro-D Pins, Terminals, etc)
• Overmolding techniques can include straight and • Komax BT-188T Twister
right-angle mechanical strain relief in a variety of • Schleuniger: Cut/Strip Coax Cable
backshells as well as overmolded in SantoPrene® • Jetec: Ink Jet Marking
and other elastomeric materials • Braiding Machine

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Testing and Environmental Screening: Qualification/Inspection & Test Lab Capabilities:
• Design and Development of Test Equipment • Tensile Strength
• ESS Testing: Temperature, Humidity, Random-Axis • DWV/IR/Hi-pot/ESD
Vibration, Shock and Leak • Vibration
• Full Functional Testing to exercise components • Immersion & Altitude
(automated/manual) • SI Analysis
• In-Circuit Testing with JTAG and Software • Cycling and Shock
Development Capabilities • Temperature
• EMI/EMC Testing • Corrosion
• Continuity and Isolation Testing for Cable Harnesses • EMI/ESD
• Optical Integrity
• Continuity
• Materials/Metallurgical lab
• Vacuum and radiation chambers

Quality Certificates:
• AS9100/EN9100 – Aerospace Industry Standard • ISO 9001:2008
• NADCAP – Electronics Certification • ISO 14001:2015
• FAA Repair Station (North America and Europe) • IPC J-STD-001
• Air Agency Certificate • MIL-STD-790
• Part 21-G • IPC/WHMA-A-620
• J-STD-001 certified • IPC-A-610/620

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MILITARY & COMMERCIAL AEROSPACE

Amphenol is at the leading edge of the latest products

and technologies demanded by the military aircraft,
commercial aircraft, and rotorcraft markets. Whether
it’s proven legacy aircraft, the newest unmanned aircraft
or rotorcraft, or the most technologically advanced
future aircraft, Amphenol designs, builds, installs,
and maintains Electrical Wiring Interconnection
Systems (EWIS) as well as high-speed, high-reliable
ruggedized product solutions for all subsystems to
keep these aircraft flying.

Aerostructure Cable Assemblies: Unpressurized Cable Assemblies:

• Electrical harnesses for all aerostructure applications • Electrical harnesses in engine and all
• Build-to-specification and/or build-to-print capabilities unpressurized areas
• EWIS compliance and aircraft certification • Build-to-specification and/or build-to-print capabilities
support available • Wiring diagrams, product change management,
configuration management and electrical testing

Engine Harnesses: Avionics Rack and Virtual Unit:

• Temperature/abrasion/EMI-resistant over-braiding • Small VU to more complex racks
for harsh environment applications • Complete integration and test
• Complex harnesses utilizing high-temp Amphenol • Mechanical, stress and electrical simulation
engine connectors and backshells • Aluminum or composite structures
• APU Cables

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Power and Signal Harnesses: In-Flight Entertainment/In-Seat Power:
• Wired panels, boxes, and chassis • Power and data to the seat
• Utilize Amphenol connectors, terminal blocks, relay • Rapid configuration Management
sockets, and system attachments
• Databus couplers

High-Speed Data Transmission Cables: Rigid Flex Jumpers:

• Used in Com Air and military aircraft for high speed • Custom design for any connector and configuation
data transfer (BtB, I/O to BtB)
• Utilizes high speed interconnects such as Octonet and • Lightweight cable replacement with simplified assembly
Oval Contact Systems for speeds of 10Gbps per channel • Shielding and grounding options
• Custom layouts and signal routing available

Flex Printed Circuit: RF and Microwave Cable Assemblies:

• Light weight cable replacement design • Semi-rigid and flexible RF cable assemblies
• Possible weight saving in excess of 70% vs standard • Precision trimming and delay matching to +/- 1 ps
wire harness • Custom bends on CNC machine
• Large format, multi-layer
• Shielding and grounding options

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MILITARY & COMMERCIAL AEROSPACE

MilTech Cable Assemblies: Flight Test Installation Harnesses:

• Designed and qualified to the harshest require- • Cables designed and built to the aircraft certification
ments of military aircraft for measuring and monitoring flight data
• Assemblies vapor sealed to assure prevention of • Harnesses can be integrated into the aircraft on the
contamination ingress customer’s Final Assembly Line (FAL)
• Connectors used have standard RF interfaces,
self-locking variants, and multiport connectors

Fiber Optic Cable Assemblies: Optical Flex Circuit:

• Connectors include: ARINC801, CF38999, EN4165, • Routes the fiber on multiple stacked substrates to
NGCON & ARINC 600 achieve compact routing
• Inflight Entertainment (IFE) and Commercial/Military • Ruggedized and quickly replaceable
Avionics applications • Available in any routing scheme
• Expanded beam, MT Fan out, Splitters and
Hybrid solutions

Data/Media Converter: Fuel Resistant Cables:

• Copper to Fiber and Fiber to Copper • For use in fuel tank environments
• Protocol Independant and Ethernet Media Conversion • Special sealing overmold design to eliminate risk of
• Multiple protocol available (XAUI, 10G Base T, HDMI) fluid intrusion into connector
• Multiple form factors (38999, VPX, Stand alone)

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SPACE SYSTEMS

Amphenol has a rich history with space-related product

developments found on many of the landmark space
achievements over the years. As the market transitions
to incorporate more commercial space development,
Amphenol is working closely with the industry to ensure
we’re leading the design of interconnect solutions for
the next generation of space exploration to Mars and
beyond for both launcher and payload applications.

SiO2 Cable Assemblies and Systems : Microwave Assemblies:

• Extreme Temperatures, Enhanced Phase • Precision trimming and delay matching to +/- 1 ps
Performance, Demanding and Exotic Environments • Up to 67Ghz
• High radiation capabilities • Custom connector designs available
• Crack-free, fired glass seal connectors • High performance Times Microwave Systems
Phasetrack and Space Flight cables available

Multi-Port Microwave Assemblies: Power/Control-Command Flight:

• Lightweight solutions • 2D or 3D cabling boards can be used to ensure the
• High density interconnection systems perfect integration
• Standard interface and custom multiport • Cleanroom manufacturing (5 total worldwide)
designs available
• Improved electrical performance
• > -90 dB shielding , low VSWR

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GROUND SYSTEMS & VEHICLES

Amphenol leads the military ground vehicle market

with interconnect solutions. Current and future ground
vehicles demand more sophisticated onboard C4I
systems, power distribution, and active protection
systems. Amphenol’s innovative engineering and diverse
product offerings meet and exceed the challenges of
SWaP, high speed, and material restrictions for any
vehicle sub-system.

Ruggedized Ethernet & USB Cables: RJ Field & USB Field Cord Sets:
• High Rel Ethernet (Cat5e/6A/7) & USB (2.0/3.0) cables • Ruggedized RJ45 & USB connectors
• UV resistant polyurethane HFFR jacket • 38999 Series III (TV) and 26482 (PT) shells
• Large choice of connectors RJF, USBF & 38999 per • 100% tested on data rate
MILVA NGVA, Quadrax contacts

Tactical Fiber Optic Cable Assemblies:

Miniature Ethernet Cord Sets:
• Connectors include: TFOCA, TFOCA-II, TFOCA-III,
• Miniature 10Gb µCom cordsets THD, THDM, TACBeam®, CTOS
• Ethernet in size 8 contact format with Quadrax & • Thermal cycling, high-temperature aging, and
Octonet (1Gb & 10 Gb) contacts
environmental testing services
• 100% tested on data rate • 100% optical performance testing

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Overbraided Harnesses: Power Generation and Distribution:
• Uses braiding materials such as PEEK, Stainless • MIL-DTL-22992 Class L connectors for shelters
Steel, PTFE, Nylon • High voltage cables for hybrid drives and on-board
• Used where extra protection is needed for harsh vehicle power (OBVP)
environments • Low voltage, multi-branch harnesses for
• Improved abrasion resistance vetronics power

Overmolded Cable Assemblies: Encapsulated Harnesses:

• Custom geometry and cable routing • Cables protected with heat-shrink sleeve
• Added protection to wire jacket and conductors • Used where extra protection is needed for harsh
• Replaces backshell and hardware; IP67 sealed environments
• Quick-turn mold design and manufacturing • Reduced susceptibility to ingress from foreign
object debris

Conduited Harnesses: Standard Harnesses and Cable Assemblies:

• Various conduit materials available • Typically open-loomed or over-braided to precise
• Good abrasion resistance electrical systems
• Typically used on land vehicles • Meet RTCA DO160 and MIL-STD-810 qualification
standards

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C4ISR & SOLDIER SYSTEMS

In the ever growing market of communications and

surveillance, Amphenol provides a reliable, rugged, and
innovative array of products to support the important
task of information collection. From powering individual
systems to providing secure and efficient transfer of data,
Amphenol has the technology to accommodate any C4ISR
application. Amphenol allows our soldiers to continue to
obtain the most important resource of all, knowledge.

MIL-DTL-55116 Audio Cables: Headset & Soldier Accessory Cables:

• For harsh environment applications using Amphenol • Soldier-worn and ruggedized tactical communication
M55116 connectors cable assemblies using various Amphenol
• Rugged, watertight, two-stage molding process connectors (2M, Terrapin, MRC)
• Finished, turnkey, factory-assembled, and molded • Overmold technology withstands harsh environments
cable assemblies • Meets many SWaP (Size, Weight, and Power)
requirements

AN/PRC-117G & 152 Military Radio Cable Adapters:

Data Cables: • Adapters can be designed and built using many
• Interface with ruggedized laptops, intercom systems common connectors
• Available as field-installable connector kits and/or • Choose the connectors and cable length to make an
factory assembled molded cable assemblies on-demand cable
• Features a rugged, watertight, two-piece metal shell • Custom cables are available
design; EMI

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2M Cable Accessories: RF and Microwave Cable Assemblies:
• Backward compatible and intermateable • Fits all standard interfaces including: SMA, 2.92mm,
to Mighty Mouse 2.4mm, SMP, SMPM & SMPS
• Booted or Overmolded solutions available • Low solder wicking and high flexibility allows for
• Fully tooled on most common sizes tight bends behind the cable ferrule
• Cost competitive against competition • Standard and custom cable options available

Fiber Optic Cable Assemblies: Expanded Beam Fiber Optics Cable Assemblies:
• Single-mode and multi-mode cable assemblies with • TACBeam, CTOS, TFOCA-XBT
D38999 III connectors • Large beam for easy transmission
• Range from simplex jumpers to multi-fiber • Supports both multi-mode and single-mode fiber
custom assemblies • Expanded beam technology is less susceptible to
• Reduced size and weight + high data rate capacity dust and debris

Loopbacks: Woven Ribbon Harnesses:

• Loopback TFOCA, TFOCA-II®, and TACBeam® • Custom flat ribbon cable
plug configurations • Configurations can be designed to match bespoke
• Used for maintenance and troubleshooting of the customer requirements
tactical cable reels and systems • Very useful in with extreme packaging constraints
• Loopback plugs come in a variety of configurations
from 0 dB to -23dB

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MILITARY RADARS & SENSORS

Reliability is the most important aspect of interconnect

design for military radars and sensors. The systems need
to work perfectly every time, without fail. Amphenol has a
wide range of high-reliable, high-speed, high-bandwidth
products that reduce SWaP: from micro-miniature and
backplane connectors to RF and microwave products,
power cables and rigid-flex assemblies, to ensure
effective missile defense.

Micro-D Assemblies: Avionics Sensor Cables:

• Micro-D connectors qualified to M83513/3 and /4 • Power distribution and avionics
• Cost-effective and reliable crimp solutions • Utilizes multiple standard connectors: D38999, MIL-
• Custom backshell and mold transitions DTL-5015, MIL-DTL-26482, and ARINC
• Fully tested and qualified assemblies • Simple point-to-point or multi-branch harnesses

Custom Molded Cables for Harsh High-Speed Copper Cable Assemblies:

Environments: • Quadrax, differential twinax, and other high-speed
• High performance injection-molded cable assemblies copper products
• Mold library supports most Amphenol and Mil-Spec • Rigid testing performed on 100% of cables before
connectors they’re shipped
• Potting and encapsulation with MIL-M 24041 epoxies • Wide range of Mil-Spec and special connector designs
used with many hybrid and custom builds

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SiO2 Cable Assemblies: Low Smoke Zero Halogen Coaxial Cables:
• Cable operating temperature -273° to +1000° C • Fully QPL’d designs per Mil-DTL-17
(-273° to +600° C assembly) • Low-Smoke, Low-Toxicity, Non-Halogen designs
• Operating pressure range 0 to 10,000 PSI • Meets IEEE-383 flame performance requirements
• Ultimate in phase tracking performance

MediaTac Cable Assemblies: PhaseTrack Cable Assemblies:

• Harsh environment fiber optic active cable assemblies • For applications demanding minimal phase change
• Active plug eliminates system redesign when over temperature
converting to fiber optic transport • Superior phase stability; PTFE ‘knee’ is non-existent
• Supports simplex or full duplex transport over a • Products include semi-rigid and flexible cables
single fiber

LMR Flexible Coaxial Cable: Electrical Assemblies:

• System of low loss coaxial cables, connectors, • Complete chassis design and manufacturing capabilities
installation tools and accessories • Vertically integrated including cabling, machining,
• Used in internal equipment wiring, cabinet, base CCA assembly, electrical and functional testing
station, and antenna jumpers • Leverage Amphenol content from multiple sources
• Flexible, low-loss, non-kinking, easy connector
attachment

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NAVAL

Amphenol is an industry leader of harsh environment

electronic interconnects servicing the Naval
market. Whether powering vital control systems,
initiating countermeasures, or transmitting critical
communication data; Amphenol’s broad product
offerings and high reliability ensure a safe and
successful mission. We take pride in supporting the
Naval market and will continue to provide our highest
level of technology, quality, and service to do so.

Shipboard Assembly : Pierside and Shipboard Fiber Optic :

• Armored cable and protections • Pierside umbilical cables handle the rigors of
• Low smoke/Zero Halogen Cable deployment and harsh environment
• Utility hardware, cable grips • Shipboard low back reflection, such as RF-over-fiber
• Custom strain relief systems or fiber optic sensor systems
• Multiple NavSea-qualified designs

Microwave Cable and Multiport Assemblies: Rugged and Engine Harness :

• Armored • High Temperature
• Lightweight solutions • DC, RF & Fiber composite cable designs
• Available in Stainless Steel & Titanium • Custom designed connectors
• High density interconnection solutions • Overbraided for abrasion resistance

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AMPHENOL COMPLEMENTARY PRODUCTS

Amphenol Military & Aerospace Operations

(AMAO) is the largest supplier of interconnect
products in the military and aerospace markets.
Our cable assembly design teams will work jointly with our connector design teams to provide custom wiring
interconnection solutions or to develop next generation technology. No other cable assembly manufacturer can match
Amphenol’s selection of cable connectors, accessories, and the guaranteed intermateability with the equipment
receptacles. Amphenol’s cable assembly expertise, combined with 21 interconnect divisions throughout North America,
Europe, and Asia, provides users a complete cable assembly solution for virtually any system.

Circular Connectors:
Mil-Spec Connectors
D38999, M26482, M83723, M22992,
M5015, M55116, M55181, M26500
D38999 Series III Terrapin
Micro-Miniature Connectors
2M, Terrapin, TAC, Bantam,
MRC, Grasshopper
Mil-Spec Derivatives
High-Power, Breakaways, High-Density,
Filter (EMI/EMP) and Hermetic Connectors

Custom Hermetic Feedthrough Circular Filter Connector Adapters

High Speed & Fiber Optics:

Mil-Spec Derivatives
RJ Field, LC Field, ARINC 801, D38999 LC Field D38999 TFOCA-III
TFOCA Connectors
TFOCA, TFOCA-II, TFOCA-III, TFOCA-XBT
High Speed Solutions
USB, Ruggedized Ethernet
Custom Designs

Rugged Ethernet RJ45 CTOS - Expanded Beam

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AMPHENOL COMPLEMENTARY PRODUCTS

Rectangular Connectors:
Rectangular Connectors
Push-Pull, Radio Data, Monomodule EN4165 AN/PRC-117G
SIM Connectors, Splices
Rack and Panel Connectors
ARINC 404, ARINC 600, IEP Interconnects
D-Sub and Micro-D Connectors
Custom Designs

ARINC 600 Micro-D

Board Level Connectors:

R-VPX

R-VPX
LRM Connectors
HiLinx
HDAS
HiLinx
SMASH
Board-to-Board Jumpers
Custom Designs

SMASH Board-to-Board Jumpers

Printed Circuit Board/

Flex/Rigid-Flex:
Standard PCBs
Flex Products Type 3 Multi-Layer Flex Rigid-Flex

Rigid-Flex Products
Backplane Assemblies
Printed Electronics
RF Printed Circuit Boards
Circuit Card Assemblies

PCB Backplane Rigid-Flex

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 RF & Microwave Interconnects:
Mil-Spec RF Connectors

Mil-Spec RF
Multiport HD Connectors
Multiport High Density
Quarterback Series
PTNC Series
BNC Series
TNC Series
Custom Designs

Quarterback Series BNC Series

Backshell & Connector Accessories:

AS85049 Backshells
EMI/RFI Backshells
AS85049 Backshells Environmental EMI/RFI Backshells
Band Lock Adapters
Composite Backshells
Micro-D and Rectangular Backshells
Strain Reliefs
Dust Caps and Protection Caps

Micro-D EMI Backshell Alumalight

System Attachments:
P-Clamps & C-Clamps
Standoffs & Raceways
P-Clamps & C-Clamps Standoffs
Cable Separators
Harness & Hat Supports
Fairlead Blocks
Jig Board Clamps
Hydraulic Pipe Supports

Fairlead Blocks Cable Supports & Separators

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THE AMPHENOL ADVANTAGE

Amphenol Military & Aerospace Operations (AMAO) offers unique advantages that no other
interconnect manufacturer can. The unique combination of interconnect expertise and harness
manufacturing capabilities enables us to offer the optimum solution at the design phase by leveraging
our connectors and wire management and harness solutions, with the goal of reducing weight,
installation and maintenance times, as well as optimizing cost.

Global footprint, local support:

With 21 divisions in North America, Europe, and Asia, we can provide a local, regional presence to
design and build any interconnect solution.

Cost-effective partnerships:
AMAO utilizes a vertically integrated supply chain to flow down the most competitive costs to our
customers, even on the most complex solutions.

Manufacturing versatility:
Many AMAO interconnect solutions have dual-production locations and off-set options (Mexico,
Estonia, India, and China) which means our customers benefit from low-cost options without the fear
of a single-source position.

Technology proliferation from other Amphenol divisions:

As the 2nd largest interconnect company in the world, we’re highly diversified and can provide our
proven COTS technology from the antennas, sensors, industrial, and automotive markets to the
military and aerospace world.

Amphenol Military & Aerospace Operations is perfectly aligned to provide the latest technologies,
cost-effective manufacturing and supply chain management, and local support to solve any military
and aerospace interconnect need.

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GLOBAL LOCATIONS

Amphenol Aerospace Operations Amphenol Griffith Enterprises Amphenol Interconnect India

40-60 Delaware Avenue 6000 East Coury Drive 105, Bhosari Industrial Area
Sidney, NY 13838 Cottonwood, AZ 86326 Pune – 411 026 India
800-678-0141 928-634-3685 +91 20 27120363

Amphenol Commercial Air Division Amphenol Canada Amphenol Japan, Ltd.

40-60 Delaware Avenue 605 Milner Avenue 471-1, Deba, Ritto-City
Sidney, NY 13838 Toronto, ON Canada M1B 5X6 Shiga, 520 3041 Japan
1-800-687-0141 416-291-0647 +81 77 553 8501

Amphenol Nexus Technologies Amphenol Invotec Amphenol Martec Limited

50 Sunnyside Avenue Unit 1-3, Hedging Lane Industrial Estate St. Augustines Business Park
Stamford, CT 06902 Dosthill, Tamworth, B77 5HH United Kingdom Swalecliffe, Whitstable, Kent
CT5 2QJ United Kingdom
203-327-7300 +44 (0) 1827 263250
+44 (0) 1227 793 733
Amphenol PCD Amphenol Ionix Systems
Amphenol Optimize
72 Cherry Hill Drive Prospect House, Taylor Business Park
Carretera Internacional Km 6.5
Beverly, MA 01915 Risley, Warrington, WA3 6HP United Kingdom
Col. Parque Industrial
978-624-3400 +44 (0) 1942 685200 Nogales, Sonora, México. C.P. 84094
Amphenol SV Microwave Amphenol Limited +52 (631) 311-160
2400 Centrepark West Drive Thanet Way Amphenol Ionix Systems OÜ
West Palm Beach, FL Whitstable, Kent, CT5 3JF United Kingdom Pikk Street 59b
561-840-1800 +44 (0) 1227 773200 Kuressaare 93815 Estonia
Amphenol Times Microwave, Inc. Amphenol Socapex +372 4521 780
358 Hall Avenue 948 Promenade De L’Arve – BP 29 AMAO – European Sales Operations
Wallingford, CT 06492 74311 Thyez France Via Barbaiana 5
800-867-2629 +33 (0) 4 50 89 28 00 20020 Lainate Milano, Italy
+39 02 932 541
Amphenol Fiber Systems International Amphenol Air LB SAS
1300 Central Expressway North, Suite 100 2 Rue Clément Ader, Zac de Wé Amphenol Bar-Tec Ltd.
Allen, TX 75013 08110 Carignan France 3 Hagavish st
214-547-2400 +33 (0) 03 24 22 78 49 POB 2479 Kfar-Saba 44641
Israel
Amphenol Borisch Technologies Amphenol AirLB GmbH +972-9-7644100
4511 East Paris AVE Am Kleinbahnhof 4
Grand Rapids, MI 49512 D-66740 Saarlouis Germany
616-554-9820 +49 (0) 68 31/98 10 0
Amphenol Printed Circuit Board Technology Amphenol SEFEE
91 Northeastern Boulevard Z.I. des Cazes – BP243
Nashua, NH 03062 12402 Saint-Affrique Cedex France
603-324-4500 +33 (0) 5 65 98 11 00

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