In military and aerospace environments, where space and weight are at a premium, reliable, compact interconnect solutions are critical to mission success. Xact EMS, an AS9100-certified and CMMC Level 2-compliant manufacturer, specializes in custom overmolded cable assemblies engineered to deliver high performance in space-constrained, high-risk applications.
Our overmolded military connectors provide exceptional durability and protection while reducing overall size and weight — a key requirement for modern defense and aerospace systems. Through precision overmolding techniques, we create high-density, robust assemblies that ensure reliable performance under extreme conditions, including harsh environments, heavy vibration, and electromagnetic interference (EMI).
Key Benefits of Xact EMS Overmolded Cable Assemblies:
- Compact & Lightweight – Engineered for space-saving installations without compromising performance.
- Enhanced Mechanical Strength – Integrated strain relief and ruggedized housings withstand demanding field conditions.
- Superior EMI Shielding – Protects critical signals from interference for secure, uninterrupted communication.
- Environmental Protection – Sealed against moisture, chemicals, dust, and extreme temperatures.
- Fully Customizable Designs – Tailored configurations to meet specific application needs and form factors.
Military-Grade Connectors We Specialize In:
- MIL-DTL-38999 – High-density circular connectors with robust EMI protection for aerospace and defense platforms.
- MIL-DTL-5015 – Rugged connectors for power and signal in military ground vehicles and heavy equipment.
- MIL-DTL-26482 – Compact bayonet connectors ideal for avionics, ground systems, and tactical comms gear.
- MIL-DTL-83513 (Micro-D) – Miniature, high-density connectors used in UAVs, missile systems, and portable electronics.
- MIL-DTL-24308 (D-Sub) – Reliable connectors for data and control systems in military and aerospace applications.
- MIL-DTL-83723 – Circular connectors designed for high-vibration and high-temperature environments.
- ARINC 600 & 404 – Modular aerospace connectors for complex avionics, communications, and navigation.
- VG95234 – Reverse bayonet connectors commonly used in military communications and field equipment.
Engineered for Space-Constrained, Mission-Critical Applications:
Xact EMS’s overmolded solutions are built to meet the evolving needs of modern defense and aerospace platforms, including:
- Fighter jets and rotary-wing aircraft
- Portable soldier communication and targeting systems
- UAVs, drones, and autonomous defense technologies
- Guided missile and munitions systems
- Field-deployable networking and command units
- Military ground vehicles and tactical control systems
Why Choose Xact EMS?
When weight, size, and reliability matter most, Xact EMS delivers rugged, compact, and high-performance overmolded assemblies that are trusted in the field and in the air. We partner with leading defense and aerospace OEMs to design and manufacture custom solutions that meet the toughest operational and environmental standards.
Xact EMS — Your trusted source for compact, durable, and mission-ready overmolded cable assemblies.
