Reliable connectivity in extreme conditions Designing connectors for harsh environments

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Powell Electronics

GGB Heilbronn GmbH

Electrical connectors used in aerospace, defence, and space applications face a unique set of physical and operational stresses. From intense vibration and electromagnetic interference to temperature extremes and corrosive atmospheres, ensuring signal integrity and power delivery under such conditions requires tailored engineering approaches. The SP Max connector series from Positronic is one such solution developed with these environmental and application-specific demands in mind.

From desert-based defence systems to orbiting spacecraft, environments that challenge standard electronic hardware demand specialised connector systems. Harsh environments may involve high vibration, rapid temperature fluctuations, electromagnetic interference, or exposure to moisture, dust, and corrosive agents.

In defence and automotive platforms, shock and vibration are constant factors. In aerospace or space applications, radiation and outgassing restrictions further complicate design. In all these cases, connectors must ensure continuous performance and reliability — even under limited visibility and confined installation space.

A growing design priority is the reduction of Space, Weight and Power (SWaP), particularly in airborne and spaceborne systems where every gram impacts payload efficiency and operational endurance. The challenge is to balance weight reduction with mechanical robustness and sufficient electrical capacity. Meanwhile, EMI/RF shielding remains a fundamental requirement in systems where data integrity and signal clarity are mission-critical.

Addressing harsh conditions: The SP Max connector solution

The Positronic SP Max series has been developed specifically to address the above requirements in demanding environments such as military ground vehicles, satellites, and aerospace systems. The SP Max connectors are built to operate reliably across a wide temperature range (–55 °C to +175 °C), enabled by liquid crystal polymer (LCP) insulation and aluminum housings engineered for heat dissipation.

For installations in restricted or low-visibility locations — common in defence platforms and avionic systems — the SP Max includes blind mating capabilities with tolerance for up to 2 mm misalignment. This feature is particularly relevant for modular or rapidly serviceable systems, such as Line Replaceable Units (LRUs).
 SP Max connectors support high current loads of up to 35 A per contact at a 30 °C temperature rise. With a compact footprint and support for 500 mating cycles, they are well suited to applications where both high reliability and low weight are essential. Configurations include fixed and removable contacts, quick-locking hardware, and multiple mounting and alignment options, making the system adaptable across diverse platforms.

Technical specifications and standards

• Compliance with EN4165, ESA/ESCC-3401, DO-160, ASTM E595 (low outgassing), FAR-25-853(a), and FAR-25-855(d)
• UL 94V-0 flammability-rated LCP insulators
• EMI/RF shielding integrated in housing design

• Contact resistance: down to 0.5 mΩ
• Insulator resistance: 2.5 GΩ
• Operating voltage: up to 600 V RMS
• Proof voltage: up to 2200 V RMS

These performance characteristics make the SP Max system suitable for both high-power and low-level signal transmission under difficult environmental conditions.

Application areas

SP Max connectors are used in a wide range of critical systems where power and signal reliability are non-negotiable. These include:

• Military and aerospace LRUs
• Satellite and deep-space communication modules
• High-wattage switchable power supplies
• Power and signal distribution in sealed enclosu
• Ground, airborne, and orbital transport platforms

• Renewable energy and mobile systems with temperature and EMI constraints

The connectors are also deployed in modular or repairable system architectures, where ease of maintenance and durability are as important as performance.

Conclusion

Extreme environments continue to push the boundaries of component design in aerospace and defence. Electrical connectors, though often overlooked, play a central role in enabling reliable operation under these demanding conditions. The Positronic SP Max series addresses these challenges through a combination of mechanical resilience, electrical capacity, and environmental compliance — all within a scalable and configurable framework.
As mission requirements become more complex and environments more extreme, component-level solutions like SP Max offer a foundation for long-term operational reliability.

For detailed technical information, layout options, or integration support, visit www.powell.com or contact posiinfo@powell.com.