Interconnect

Custom Mil-Spec Connector Components

Projects

We’ve completed thousands of interconnect projects over the years, ranging from micro and nano miniature connector components to high-density components and contract manufacturing of circular and rectangular connectors. Commonly, our customers stem from the aerospace industry and require high-quality MIL-Spec connector components for varying applications. Some examples of projects we have completed are:

  • Aerospace & Defense
    • Aircraft flight and engine control components
    • Aircraft communications devices
    • Active vibration control systems
    • Weapons controls systems
    • Flight control surface and engine actuators
    • Actuator control components
    • Avionics boxes
    • Avionics harnessing and connectors
    • Spaceflight control components
    • Soldier connectivity devices
  • Test Gauges for interconnect production
  • Interfacial Seals from materials such as Fluorosilicone
  • Insert molded Connectors (Metal & Plastic)
  • Military Spec Components
    • PCB Connectors
    • RF Connectors
    • Power Connectors
  • Connectors of varying shapes & sizes
    • Nanominiature Connectors
    • Rectangular Connectors
    • Circular Connectors
    • Microminiature Components
  • High-Density Components
  • Fiber Optic Interconnect Components

Materials

EDM strives to meet your needs. Through our strategic partnerships with a vast array of qualified material suppliers, we can manufacture components using the exact materials that you require, all while meeting strict quality standards. In the interconnect world, we commonly work with:

  • High Performance Materials
  • LCP with glass fiber reinforcement
  • ULTEM Thermoset material injection molded
  • PEEK
  • PPS Ryton
  • PFA Teflon
  • Nylon
  • Polyethylene (Dust Caps)
  • Fluorosilicone (Interfacial Seals and Grommets)
  • Thermoset Materials

Standards of Compliance

EDM Department is a company committed to quality. We understand that every component of a connector needs to be manufactured with utmost precision and accuracy. For this reason, we are proud to adhere to your specified requirements. Over the last 20 years, we’ve manufactured connectors and connector components in accordance with the following standards and as a result have a deep knowledge and understanding of what it takes to completed projects with these stringent requirements:

  • MIL-Spec 24519 Spec
  • ASTM-D-5138
  • MIL-Spec 83513 (Micro-D)
  • MIL-spec 32139 (Nano-D)
  • MIL-spec 38399 (Series I, II, III and 5015)

Capabilities

As our name suggests, our core competencies are, and always have been, Wire EDM and Sinker EDM. However, utilizing our diverse and talented team, we supplement these capabilities with additional machining options which strategically complement and enhance our abilities. Companies that specialize in Interconnect industry often make use of our additional manufacturing capabilities like Precision Grinding, Precision & Micro MillingRapid Prototyping, and 3D metrology. Key aspects of our capabilities include:

  • Aspect ratios up to 38:1
  • Feature sizes as small as 40μm
  • Tolerances as tight as 1 micron
  • Surface finishes of 4Ra micro inch
  • Surface roughness inspection
  • 3D part scan to 3D CAD model overlays with difference modeling
  • Prototypes, low quantity runs and batch production up to 10,000pcs

Download our Brochure

Our capabilities, project experience, materials and photo gallery all in one place! Download our brochure for a quick EDM Rapid Prototyping overview.

Download our Interconnect Industry Brochure