Category Archive: MIL-SPEC cable assemblies

Does your Application Really Need A Mil Spec Cable Assembly?

Mil Spec Cable AssemblyA mil spec cable assembly is one that has been manufactured according to military standards. These assemblies are lightweight, rugged, and durable, among other things. The materials used to manufacture military cable assemblies are also of the highest quality. These materials lower vibrations within an application, are more durable, and perform in accordance with military standards. However, not all applications require such specialized cable assemblies. Mil-spec wires can be a bit on the expensive side when compared to other normally used cable assemblies. Hence, it is important to identify your needs to understand if the extra cost is really worth it.

5 Factors to Help You Determine Your Mil Spec Cable Assembly Requirements
If you answer yes to any of the below questions, then you will benefit from mil-spec assemblies. Otherwise, you can opt for normal cable assemblies.
1. Your Application is Critical
The application in which the military cable assemblies are used is the heart of your entire process. If this application fails, it will result in heavy losses for your organization. If this is the case, you can consider incorporating mil-spec wires specifically for some parts of the application.
2. The Application or Environment is Harsh
Mil spec wires are designed to withstand harsh environmental conditions. They function across a wide temperature and pressure range, are corrosion and abrasion resistant, and can function across a wide voltage range. In short, they provide long-lasting service through demanding situations.
3. Possibility of Vibrations
Military applications are almost always in a constant state of motion and vibration. They have to traverse tough terrain and generally trying conditions. The wires built for these applications are able to function smoothly in high vibration environments. Therefore, if your application will be experiencing vibrations that are high in intensity or frequency, opting for mil spec cable assemblies is a good idea.
4. Possibility of EMI/RFI Radiations
All military grade cable assemblies are covered with EMI/RFI shielding materials. If your application will be exposed to these radiations, look for mil-spec wires or customized cables with the right shielding materials.
5. A Higher Authority Mandates You to Use Mil-Spec
Some applications are used in certain applications where a local, federal, or external body demands the use of mil-spec products. This can be done to ensure additional safety or product reliability. In such situations when it is mandatory to use military grade product, mil-spec cable assemblies need to be integrated without question.

Military cable assemblies are used in various rugged applications, which need to adhere to certain guidelines that are in line with those dictated for military applications. If you are confused about the wires and cable assemblies to be used, consult your cable assembly manufacturer. He will be able to guide you on picking up the most suitable cable assemblies for your application. If you can’t find the right match, you can even consider opting for customized cable assemblies to suit your application.

Cable Assemblies in Military Applications

Military Specification (MIL-SPECMil-spec cable assemblies and wiring harness) cable assemblies are designed to provide benefits of reliable performance and durability in demanding applications. The success of military equipment depends a great deal on the high signal integrity provided by the assemblies.

Supporting Military Applications :

MIL-SPEC cable assemblies can support personnel and equipment in various military applications. Here are a few examples:

  • Soldier Worn Systems: Many devices are worn by soldiers on the field. Cable assemblies can be designed with elastic materials, which allow the cables to be stretched when worn outside military gear. They can also be integrated into the protective armor and clothing. Various RFI shielding options can protect the devices, while maintaining high signal strength in applications with contaminants such as sand, water, and dirt.
  • Aviation: For military and aviation applications, cable assemblies are designed with high temperature wires and custom connectors. They can be constructed out of lightweight materials such as carbon fiber, rather than heavy metallic components. The connectors can comprise a simple click design for installation and removal.
  • Defense Vehicles: Vehicles like cars and trucks endure immense stress on the field. For such applications, connectors can be optimized to be lightweight and small in size. The result of this would be an increase in application space, without adding to the weight of the vehicle. Waterproof cables can be used to ensure that the vehicles do not shut down when travelling in rain, or passing through water-filled areas.
  • Communication: Military communication requires the most amount of protection, as they are used in a wide number of settings. For this application sector, cable assembly manufacturers offer material choices such as beryllium copper, tinned copper, carbon fiber, PVC, HDPE and Teflon. Custom connectors can be designed using overmolding process for improved protection. A few common applications include radios, Push-To-Talk (PTT) systems, and interconnecting headsets.

MIL-SPEC cable assemblies can prove to be extremely useful in a variety of military applications. The right choice of material and design, can lead to the manufacturing of reliable and durable products.