Products Offered

 

Proven Results

Aerospace Systems' expertise in building custom cables and harnesses that meet rigorous quality requirements enable us to make the finest products in our industry. Our customized manufacturing solutions and our dedicated employees provide you with excellence from start to finish, and every step in between.



Solid Molded

Aerospace Systems offers solid molded cable designs to withstand extreme environmental and physical abuse. Solid molded means the connector back-shell is potted and overmolded with an elastomer to provide strain relief and moisture sealing. Junctions (transitions) are also overmolded with the same compound. Overall braided and tape shields may be used to provide EMI/RFI protection. Various wire and elastomer materials are available to meet most requirements.


Advantages of Molded Construction

1. Water proof construction
2. Resilient mechanical protection of the connector.
3. Maximum strain relief effectiveness.
4. No flex induced stress on connector contacts.
5. Molding and curing process creates no stress and prevents wire insulation cold flow such as mechanicalclamps produce.
6. Excellent electrical insulation properties.
7. Less exposed metal than mechanical backshells.
8. Lower cost than shrinkable boots and EMI/RFI environmental mechanical backshells.
9. Cable can enter connector from any angle.
10. Overall 360 degree shield termination can not be disturbed.

Molded Field Repairable

The Aerospace Systems field repairable molded design has all the advantages of the solid molded design plus the advantage of repairability. The coupling nut of this design may be unscrewed from the backshell to reveal a service loop of wire within the backshell. Contacts or the connector may be replaced or rewired without disturbing the shield termination. When reassembled using standard hand tools, an O-ring seals the unit against the environment. Spare wires may be added to the cable to allow for expansion. This design is especially useful for test cable equipment since wiring schematics may change over time. Repairing, rather than scrapping, an expensive cable is another reason to utilize field repairable assemblies.
 



Wire Harnesses
 

Higher-Level Assemblies
 

Through higher-level assemblies all of our capabilities can interoperate, drawing on the very best all we have to offer: The best minds, the best facilities, the best materials and the best components.

• Wiring together cables, sheets and circuit cards to produce a higher level product
• Wire circuit cards to connectors, building cable assemblies or harnesses
• Making and machining all original components
• Kitting
• Integration of kitting and higher level builds
• Heated hose applications

These are only examples in a range of possibilities: the sky is far from the limit. Additional products offered include:

Mechanical Assemblies
 
 
Flat Molded

Flat Molded Cable Assemblies Design Considerations:

The following is a short description of design suggestions for use in your flat molded cable designs.

The objective is to provide for the maximum flexibility, a very thin package and produce a product that meets or exceeds the electrical and environmental performance requirements, all while keeping cost to a minimum.

Cast polyurethane flat cable assemblies are a least cost alternative and more rugged than flexible and semi rigid printed wiring boards, especially when the physical size is large and/or the production quantity is small to medium.

WIRE SELECTION:

1.       MIS-35755 Wire and cable, Ultra- flexible, FEP insulated.

  • Available in Type U and S, unshielded and shielded, respectively.
  • Range 20 to 28 AWG, 24 AWG suggested with insulated OD 0.024 inch.
  • Very high stranding supports high flex and excellent electrical properties.
  • White single conductor, red and white two conductor cables, and white, red and black three conductor cables.
  • This wire and cable is recommended as component wires in cast polyurethane flat cable assemblies by US Army Missile Command. Not for use as hook-up and in open wiring harnesses.

2.       MIL-W-22759/32 Wire.Suggest AWG 24 to 30 to maintain flexibility.

  •  All colors available, but various colors not needed, as reparability is limited.
  •  Less expensive, but not as flexible as MIS wire.
CABLE MOLDING COMPOUND SELECTION:
  • MIS-35759B Polyurethane cable molding compound. Aerospace Systems standard material for the cable mold is Hysol US-4028 amber. (CAGE CODE 12405)
  • Considered as a missile standard for flat cable molding compound.

CONNECTOR MOLDING COMPOUND SELECTION:

  • MIS-35273F Application of polyurethane and epoxy molding compounds.
  • Two types I and II and three classes A, B and C. Selection is based on service application and flexibility. Temperature range from –54 degrees to + 200 degrees F. Hardness from 45 Shore A to 80 Shore A, softer is more flexible. Suggest type I, class B. 
  • For class A, Shore A hardness 70 minimum, consider Mil-M-24041 Cat B, Type 1, Molding and potting compound, color black. Aerospace Systems standard material for connectors and junction molds is Cytec EN-1556 (CAGE CODE 16245) with a standard Shore A hardness of 80.
OVERALL SHIELDING:
  • CHO-FLEX 501, CAGE CODE 18565 coating or alternate 73-00008, CAGE CODE 07700.
  • Overall shielding protective coating CHO-SHIELD 4937 or alternate 73-00009, CAGE CODE 07700.

MOLDING APPLICATION NOTES:

  •  Aerospace Systems suggests that the minimum spacing between the OD of insulated component wires or between the OD of two and three conductor shielded cables be 0.015 inch. This 0.015 inch minimum applies also to the edge conductors and the edge of the molded cable, and the conductor OD and the surface of the cable.
  • Overall molded cable thickness using MIS 24 AWG wire thus calculates to be 0.054 inch, we suggest a note stating that the molded cable should be 0.065 inch maximum to allow of manufacturing tolerances.
  •  Surface voids should not exceed 0.030 inch diameter. Voids extending below the surface should not exceed 0.060 inch diameter. Mold separation lines are acceptable.

Fiber Optics
 
The following is a description of basic capabilities and suggested design specifications for use in your fiber optic cable assemblies. Aerospace Systems provides high quality fiber optic assembles which meet or exceed MIL-STD-2042 requirements.

CONNECTORS

  • MIL-C-28875 connectors for multiple termini
  • MIL-C-83522 connectors for single terminus
  • Commercial grade ST connectors
  • Commercial grade SC connectors
  • Commercial grade FC APC connectors (reduced return loss)
CONNECTORIZATION
 
  • Epoxy (shipboard approved) – Most common
  • Pre-loaded adhesive
  • Crimp
  • Chemical (ovenless)
  • UV Curable

TERMINI

  • MIL-T-29504/14 and /15 for MIL-C-28876 connectors
  • MIL-T-29504/4 and /5 for MIL-DTL-38999 connector 16 AWG contact cavities
  • Non-military spec contacts for MIL-DTL-38999 connector 20 AWG contact cavities

POLISH TYPES

  • Physical Contact (PC) both flat and domed
  • Enhanced polish
  • FC APC
  • Multi and single mode
     

CABLE

  • MIL-PRF-8045 includes all types of cable including multiple fiber multi and single mode
  • Custom hybrid cables (combined multi and single mode)
  • Custom composite cables (combined optical fiber and copper conductors)
  • Commercial cable

INSPECTION/TESTING

  • 400X Visual Inspection
  • Insertion loss for multi and single mode
  • Return loss for single mode (+6 to –60 dbm)

TRAINING AND METHODS

MIL-STD-2042 trained personnel to insure quality. All assemblies built to MIL-STD-2042 requirements.

 MOLDED STRAIN RELIEFS

Any type of connector can be overmolded to provide superior strain relief. With suitable connectors a waterproof, rugged fiber optic cable assembly is achievable.

 
 

 

Coax Assemblies