Custom Mil-Spec Connector Components


Interconnect - EDM Department
Interconnect - EDM Department

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
Interconnect - EDM Department
Interconnect - EDM Department


EDMIS 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


EDM Intelligent Solutions 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)


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 the 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


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


Creating intelligent solutions for manufacturing and measurement challenges is what we do. Over the past 25 years, we’ve completed thousands of measurement and metrology projects. What differentiates EDM Intelligent Solutions 3D Metrology Systems from the competition is our team’s unique understanding of how our systems can be applied to almost every manufacturing process.

The EDMIS team of metrology technicians and applications engineers support their colleagues in our tight tolerance CNC machine shop that produces ultra-precision components for customers every day. Harnessing this unique relationship with manufacturing, our metrology team has the experience needed to fully assist our customers integrate EDMIS metrology systems within their manufacturing processes to leverage 3D measurements to improve both their manufacturing processes and products. We are confident that we have a system that can measure your most challenging components and we are ready to work with you to fully understand your metrology needs. To learn more about how EDMIS can help you, contact our metrology team with your request for quote.