en.Wedoany.com Reported - Molex has expanded its AirBorn SInergy modular high-speed hybrid connector product line with new heavy-duty high-power contacts, supporting power transmission up to 25.0A in standard module slots—12.5 times the power capacity of the previous version. This product is designed to address compact system layouts in harsh environments while providing high-power support.
Billy Rhea, Product Director of the Aerospace and Defense Solutions Group at Molex, stated that the rapid evolution of next-generation aerospace and defense systems requires an exponential leap in power transmission. This expanded version allows customers to mix and match high-power, high-speed data, and RF contacts, providing an integrated connectivity solution to accelerate design capabilities.
The new power module enables design engineers to address the large-scale expansion required to support high-energy applications such as aircraft launch systems, advanced radar, avionics, satellites, and combat vehicles. The AirBorn SInergy connector combines high-density signal contacts supporting data rates up to 25 Gbps and RF contacts supporting up to 40 GHz, suitable for space-constrained designs with complex geometries. The platform features up to five interchangeable connector slots that can be configured with different contact types, enabling any combination of signal, power, and RF modules. Compared to fixed-layout hybrid products, SInergy offers per-position configuration flexibility, allowing engineers to place specific contact types exactly where needed. A single-slot connector is approximately the size of a U.S. quarter, and with multiple mounting options, it optimizes mechanical alignment and mating security.
By replacing single-function connectors with an integrated customizable platform, this product reduces the bill of materials, supply chain complexity, and certification processes, thereby shortening time to market. The AirBorn SInergy product portfolio builds on the innovation legacy of the AirBorn M-Series MIL-DTL-83513 Micro-D connectors and AirBorn N-Series MIL-DTL-32139 Nano-D connectors, capable of withstanding extreme temperatures, vibration, shock, and humidity. The new power contacts are designed in accordance with the MIL-DTL-39029 contact crimp standard, supporting up to 25.0A with a rated temperature rise baseline controlled within 30°C. Derating test data indicates this performance is suitable for heat-constrained space applications.
A report released by Molex shows that over half (52%) of surveyed aerospace and defense design engineers prioritize addressing growing power demands as their top concern, with the four key technological innovations being power distribution and onboard power management, high-speed data transmission, electronic defense, and advanced sensing and perception processing. The development of the AirBorn SInergy high-power expansion is based on collaboration with global original equipment manufacturers, prime contractors, and tier-one/subsystem suppliers in the aerospace and defense industry.
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