CABLE ASSEMBLIES
Amphenol Military & Aerospace Cable Assemblies

AMPHENOL CABLE MANUFACTURING

Amphenol Military & Aerospace Operations (AMAO) has the capabilities to meet a diverse range of cable and harness
assembly needs within the Military and Aerospace markets. We have over 550,000 sq. ft. of cable manufacturing space andmultiple locations in North America, Europe, and Asia to design, manufacture, and install harsh environment cable assemblies.
Our engineers have over 40 years of experience designing cables and harnesses to a wide variety of requirements. Amphenol’s
intra-company partnerships give us access to the largest interconnect product portfolio in the Military and Aerospace markets todesign and build anything from simple point-to-point cables and pigtails to complex multi-branch harnesses. AMAO
offers the broadest range of harness technologies covering standard and aluminum wires, high-speed, fiber, hightemperature, IP67 environment, RF and Microwave, semi-rigid, and flex PCB.

Harness Design Capabilities:

Production Capabilities Include:

Electrical• 3D design and routing(CAD, including CATIA V5 Software)• Formboard for 2D definition Electrical wiring• Electrical Netlist• Design per EWIS best practices for Aerospace
Serial Design• Obsolescence management• Equipment manufacturing engineering• Primary wire extrusions/jacketing for high end applications• Experienced IPC/WHMA-A-620 certified workforce• Automated twisters, strippers, cutters, crimpers• Crimp capabilities for 777MCM to 26AWG wire
• Custom overmold presses with in-house production tooling• Twisted shielded pair and quadrax cable assemblies• Full testing capabilities for DWV, IR, continuity, etc.
• Meet RTCA DO160 and MIL-STD-810
qualification standards• Five clean rooms (class 100,000) in North America,
Europe, and Asia

Overmolding:

Automation and Quality Control:• Amphenol excels in overmolding cable technology,
perfect for ruggedized power applications• Custom overmold solutions utilize either low or
high-pressure manufacturing methods, and include
various environmental materials• Overmolding techniques can include straight andright-angle mechanical strain relief in a variety ofbackshells as well as overmolded in SantoPrene®
and other elastomeric materials• Laser and Ink Jet Marking• Label and sleeve printing• Komax: Mark, Cut, Strip, Twist, Crimp, Pull, X-Ray(Down to 32 AWG)
• AMP K-Press (Micro-D Pins, Terminals, etc)
• Komax BT-188T Twister• Schleuniger: Cut/Strip Coax Cable• Jetec: Ink Jet Marking• Braiding Machine

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Testing and Environmental Screening:

Qualification/Inspection & Test Lab Capabilities:• Design and Development of Test Equipment• ESS Testing: Temperature, Humidity, Random-Axis
Vibration, Shock and Leak
• Full Functional Testing to exercise components(automated/manual)• In-Circuit Testing with JTAG and Software
Development Capabilities• EMI/EMC Testing• Continuity and Isolation Testing for Cable Harnesses• Tensile Strength• DWV/IR/Hi-pot/ESD• Vibration• Immersion & Altitude• SI Analysis• Cycling and Shock• Temperature• Corrosion• EMI/ESD• Optical Integrity• Continuity• Materials/Metallurgical lab• Vacuum and radiation chambers

Quality Certificates:• AS9100/EN9100 – Aerospace Industry Standard• NADCAP – Electronics Certification• FAA Repair Station (North America and Europe)• Air Agency Certificate• Part 21-G
• J-STD-001 certified• ISO 9001:2008• ISO 14001:2015• IPC J-STD-001• MIL-STD-790• IPC/WHMA-A-620• IPC-A-610/620

Visit amphenolmao.com for more informationMILITARY & COMMERCIAL AEROSPACE
Amphenol is at the leading edge of the latest products
and technologies demanded by the military aircraft,commercial aircraft, and rotorcraft markets. Whether
it’s proven legacy aircraft, the newest unmanned aircraftor rotorcraft, or the most technologically advanced
future aircraft, Amphenol designs, builds, installs,
and maintains Electrical Wiring Interconnection
Systems (EWIS) as well as high-speed, high-reliableruggedized product solutions for all subsystems tokeep these aircraft flying.

Aerostructure Cable Assemblies:• Electrical harnesses for all aerostructure applications• Build-to-specification and/or build-to-print capabilities• EWIS compliance and aircraft certification

Unpressurized Cable Assemblies:• Electrical harnesses in engine and all

Engine Harnesses:• Temperature/abrasion/EMI-resistant over-braiding

Avionics Rack and Virtual Unit:• Small VU to more complex racks• Complete integration and test
• Mechanical, stress and electrical simulation• Aluminum or composite structures

support available••

for harsh environment applications
Complex harnesses utilizing high-temp Amphenol
engine connectors and backshells
APU Cables••

unpressurized areas
Build-to-specification and/or build-to-print capabilities
Wiring diagrams, product change management,
configuration management and electrical testing

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Power and Signal Harnesses:• Wired panels, boxes, and chassis• Utilize Amphenol connectors, terminal blocks, relay•

sockets, and system attachments
Databus couplers

In-Flight Entertainment/In-Seat Power:• Power and data to the seat
• Rapid configuration Management

High-Speed Data Transmission Cables:• Used in Com Air and military aircraft for high speed

Rigid Flex Jumpers:• Custom design for any connector and configuation

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data transfer
Utilizes high speed interconnects such as Octonet andOval Contact Systems for speeds of 10Gbps per channel
Custom layouts and signal routing available

Flex Printed Circuit:• Light weight cable replacement design• Possible weight saving in excess of 70% vs standard••

wire harness
Large format, multi-layer
Shielding and grounding options(BtB, I/O to BtB)
Lightweight cable replacement with simplified assembly
Shielding and grounding options

RF and Microwave Cable Assemblies:• Semi-rigid and flexible RF cable assemblies• Precision trimming and delay matching to +/- 1 ps
• Custom bends on CNC machine

Visit amphenolmao.com for more informationMILITARY & COMMERCIAL AEROSPACE

MilTech Cable Assemblies:• Designed and qualified to the harshest require-

Flight Test Installation Harnesses:• Cables designed and built to the aircraft certification

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ments of military aircraft
Assemblies vapor sealed to assure prevention ofcontamination ingress
Connectors used have standard RF interfaces,
self-locking variants, and multiport connectors

for measuring and monitoring flight data
Harnesses can be integrated into the aircraft on thecustomer’s Final Assembly Line (FAL)

Fiber Optic Cable Assemblies:• Connectors include: ARINC801, CF38999, EN4165,

Optical Flex Circuit:• Routes the fiber on multiple stacked substrates to

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NGCON & ARINC 600
Inflight Entertainment (IFE) and Commercial/Military
Avionics applications
Expanded beam, MT Fan out, Splitters andHybrid solutions

Data/Media Converter:• Copper to Fiber and Fiber to Copper• Protocol Independant and Ethernet Media Conversion• Multiple protocol available (XAUI, 10G Base T, HDMI)• Multiple form factors (38999, VPX, Stand alone)achieve compact routing
Ruggedized and quickly replaceable
Available in any routing scheme

Fuel Resistant Cables:• For use in fuel tank environments• Special sealing overmold design to eliminate risk of
fluid intrusion into connector

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SPACE SYSTEMS
Amphenol has a rich history with space-related productdevelopments found on many of the landmark spaceachievements over the years. As the market transitions
to incorporate more commercial space development,
Amphenol is working closely with the industry to ensure
we’re leading the design of interconnect solutions forthe next generation of space exploration to Mars andbeyond for both launcher and payload applications.

SiO2 Cable Assemblies and Systems :• Extreme Temperatures, Enhanced Phase••

Performance, Demanding and Exotic Environments
High radiation capabilities
Crack-free, fired glass seal connectors

Multi-Port Microwave Assemblies:• Lightweight solutions• High density interconnection systems• Standard interface and custom multiport••designs available
Improved electrical performance> -90 dB shielding , low VSWR

Microwave Assemblies:• Precision trimming and delay matching to +/- 1 ps
• Up to 67Ghz• Custom connector designs available• High performance Times Microwave Systems
Phasetrack and Space Flight cables available

Power/Control-Command Flight:• 2D or 3D cabling boards can be used to ensure the•perfect integration
Cleanroom manufacturing (5 total worldwide)

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GROUND SYSTEMS & VEHICLES
Amphenol leads the military ground vehicle market
with interconnect solutions. Current and future groundvehicles demand more sophisticated onboard C4I
systems, power distribution, and active protection
systems. Amphenol’s innovative engineering and diverse
product offerings meet and exceed the challenges of
SWaP, high speed, and material restrictions for any
vehicle sub-system.

Ruggedized Ethernet & USB Cables:• High Rel Ethernet (Cat5e/6A/7) & USB (2.0/3.0) cables• UV resistant polyurethane HFFR jacket• Large choice of connectors RJF, USBF & 38999 per
MILVA NGVA, Quadrax contacts

Miniature Ethernet Cord Sets:• Miniature 10Gb µCom cordsets• Ethernet in size 8 contact format with Quadrax &•Octonet (1Gb & 10 Gb) contacts
100% tested on data rate

RJ Field & USB Field Cord Sets:• Ruggedized RJ45 & USB connectors• 38999 Series III (TV) and 26482 (PT) shells• 100% tested on data rate

Tactical Fiber Optic Cable Assemblies:• Connectors include: TFOCA, TFOCA-II, TFOCA-III,••

THD, THDM, TACBeam®, CTOS
Thermal cycling, high-temperature aging, andenvironmental testing services
100% optical performance testing

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Overbraided Harnesses:• Uses braiding materials such as PEEK, Stainless••Steel, PTFE, Nylon
Used where extra protection is needed for harshenvironments
Improved abrasion resistancePower Generation and Distribution:• MIL-DTL-22992 Class L connectors for shelters• High voltage cables for hybrid drives and on-board•

vehicle power (OBVP)
Low voltage, multi-branch harnesses forvetronics power

Overmolded Cable Assemblies:• Custom geometry and cable routing• Added protection to wire jacket and conductors• Replaces backshell and hardware; IP67 sealed• Quick-turn mold design and manufacturing

Encapsulated Harnesses:• Cables protected with heat-shrink sleeve• Used where extra protection is needed for harsh

Conduited Harnesses:• Various conduit materials available• Good abrasion resistance• Typically used on land vehicles

Standard Harnesses and Cable Assemblies:• Typically open-loomed or over-braided to precise••

environments
Reduced susceptibility to ingress from foreign
object debris

electrical systems
Meet RTCA DO160 and MIL-STD-810 qualification
standards

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C4ISR & SOLDIER SYSTEMSIn the ever growing market of communications andsurveillance, Amphenol provides a reliable, rugged, andinnovative array of products to support the importanttask of information collection. From powering individual
systems to providing secure and efficient transfer of data,
Amphenol has the technology to accommodate any C4ISR
application. Amphenol allows our soldiers to continue toobtain the most important resource of all, knowledge.

MIL-DTL-55116 Audio Cables:• For harsh environment applications using Amphenol••

M55116 connectors
Rugged, watertight, two-stage molding process
Finished, turnkey, factory-assembled, and molded
cable assemblies

Headset & Soldier Accessory Cables:• Soldier-worn and ruggedized tactical communication••

cable assemblies using various Amphenol
connectors (2M, Terrapin, MRC)
Overmold technology withstands harsh environments
Meets many SWaP (Size, Weight, and Power)
requirements

AN/PRC-117G & 152 Military Radio
Data Cables:• Interface with ruggedized laptops, intercom systems• Available as field-installable connector kits and/or

Cable Adapters:• Adapters can be designed and built using many••factory assembled molded cable assemblies
Features a rugged, watertight, two-piece metal shell
design; EMI•

common connectors
Choose the connectors and cable length to make an
on-demand cable
Custom cables are available

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2M Cable Accessories:• Backward compatible and intermateable

RF and Microwave Cable Assemblies:• Fits all standard interfaces including: SMA, 2.92mm,

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to Mighty Mouse
Booted or Overmolded solutions available
Fully tooled on most common sizes
Cost competitive against competition

Fiber Optic Cable Assemblies:• Single-mode and multi-mode cable assemblies with••

D38999 III connectors
Range from simplex jumpers to multi-fiber
custom assemblies
Reduced size and weight + high data rate capacity

Loopbacks:• Loopback TFOCA, TFOCA-II®, and TACBeam®
••plug configurations
Used for maintenance and troubleshooting of thetactical cable reels and systems
Loopback plugs come in a variety of configurations
from 0 dB to -23dB•

2.4mm, SMP, SMPM & SMPS
Low solder wicking and high flexibility allows fortight bends behind the cable ferruleStandard and custom cable options available

Expanded Beam Fiber Optics Cable Assemblies:• TACBeam, CTOS, TFOCA-XBT• Large beam for easy transmission• Supports both multi-mode and single-mode fiber• Expanded beam technology is less susceptible todust and debris

Woven Ribbon Harnesses:• Custom flat ribbon cable• Configurations can be designed to match bespoke•

customer requirements
Very useful in with extreme packaging constraints

Visit amphenolmao.com for more informationMILITARY RADARS & SENSORS
Reliability is the most important aspect of interconnect
design for military radars and sensors. The systems need
to work perfectly every time, without fail. Amphenol has awide range of high-reliable, high-speed, high-bandwidth
products that reduce SWaP: from micro-miniature andbackplane connectors to RF and microwave products,
power cables and rigid-flex assemblies, to ensure
effective missile defense.

Micro-D Assemblies:• Micro-D connectors qualified to M83513/3 and /4• Cost-effective and reliable crimp solutions• Custom backshell and mold transitions• Fully tested and qualified assemblies

Avionics Sensor Cables:• Power distribution and avionics• Utilizes multiple standard connectors: D38999, MIL-

Custom Molded Cables for Harsh
Environments:• High performance injection-molded cable assemblies• Mold library supports most Amphenol and Mil-Spec

High-Speed Copper Cable Assemblies:• Quadrax, differential twinax, and other high-speed••

connectors
Potting and encapsulation with MIL-M 24041 epoxies••

DTL-5015, MIL-DTL-26482, and ARINC
Simple point-to-point or multi-branch harnesses

copper products
Rigid testing performed on 100% of cables before
they’re shipped
Wide range of Mil-Spec and special connector designs
used with many hybrid and custom builds

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SiO2 Cable Assemblies:• Cable operating temperature -273° to +1000° C••(-273° to +600° C assembly)
Operating pressure range 0 to 10,000 PSI
Ultimate in phase tracking performanceMediaTac Cable Assemblies:• Harsh environment fiber optic active cable assemblies• Active plug eliminates system redesign when•converting to fiber optic transport
Supports simplex or full duplex transport over a
single fiber

LMR Flexible Coaxial Cable:• System of low loss coaxial cables, connectors,••

installation tools and accessories
Used in internal equipment wiring, cabinet, basestation, and antenna jumpers
Flexible, low-loss, non-kinking, easy connector
attachment

Low Smoke Zero Halogen Coaxial Cables:• Fully QPL’d designs per Mil-DTL-17• Low-Smoke, Low-Toxicity, Non-Halogen designs• Meets IEEE-383 flame performance requirements

PhaseTrack Cable Assemblies:• For applications demanding minimal phase change••over temperature
Superior phase stability; PTFE ‘knee’ is non-existent
Products include semi-rigid and flexible cables

Electrical Assemblies:• Complete chassis design and manufacturing capabilities• Vertically integrated including cabling, machining,•

CCA assembly, electrical and functional testing
Leverage Amphenol content from multiple sources

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NAVALAmphenol is an industry leader of harsh environment
electronic interconnects servicing the Navalmarket. Whether powering vital control systems,
initiating countermeasures, or transmitting criticalcommunication data; Amphenol’s broad productofferings and high reliability ensure a safe andsuccessful mission. We take pride in supporting theNaval market and will continue to provide our highest
level of technology, quality, and service to do so.

Shipboard Assembly :• Armored cable and protections• Low smoke/Zero Halogen Cable• Utility hardware, cable grips• Custom strain relief systems

Pierside and Shipboard Fiber Optic :• Pierside umbilical cables handle the rigors ofMicrowave Cable and Multiport Assemblies:• Armored• Lightweight solutions• Available in Stainless Steel & Titanium• High density interconnection solutions

Rugged and Engine Harness :• High Temperature• DC, RF & Fiber composite cable designs• Custom designed connectors• Overbraided for abrasion resistance••deployment and harsh environment
Shipboard low back reflection, such as RF-over-fiberor fiber optic sensor systems
Multiple NavSea-qualified designs

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AMPHENOL COMPLEMENTARY PRODUCTS

Amphenol Military & Aerospace Operations(AMAO) is the largest supplier of interconnect
products in the military and aerospace markets.
Our cable assembly design teams will work jointly with our connector design teams to provide custom wiring
interconnection solutions or to develop next generation technology. No other cable assembly manufacturer can match
Amphenol’s selection of cable connectors, accessories, and the guaranteed intermateability with the equipment
receptacles. Amphenol’s cable assembly expertise, combined with 21 interconnect divisions throughout North America,
Europe, and Asia, provides users a complete cable assembly solution for virtually any system.

Circular Connectors:

D38999 Series III

Mil-Spec Connectors
D38999, M26482, M83723, M22992,
M5015, M55116, M55181, M26500

Terrapin

Micro-Miniature Connectors
2M, Terrapin, TAC, Bantam,
MRC, Grasshopper
Mil-Spec Derivatives
High-Power, Breakaways, High-Density,
Filter (EMI/EMP) and Hermetic Connectors

Custom Hermetic FeedthroughCircular Filter Connector Adapters

High Speed & Fiber Optics:

Mil-Spec Derivatives
RJ Field, LC Field, ARINC 801, D38999

TFOCA Connectors
TFOCA, TFOCA-II, TFOCA-III, TFOCA-XBTLC Field D38999

TFOCA-III

Rugged Ethernet RJ45

CTOS - Expanded BeamHigh Speed Solutions
USB, Ruggedized Ethernet
Custom Designs

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AMPHENOL COMPLEMENTARY PRODUCTS

Rectangular Connectors:
Rectangular Connectors
Push-Pull, Radio Data,
SIM Connectors, Splices

Monomodule EN4165

AN/PRC-117G

ARINC 600

Micro-D

Rack and Panel Connectors
ARINC 404, ARINC 600, IEP Interconnects
D-Sub and Micro-D Connectors

Custom Designs

Board Level Connectors:
R-VPX
R-VPX

LRM Connectors

HiLinxHDAS

HiLinxSMASH

Board-to-Board Jumpers
Custom Designs
SMASH

Board-to-Board Jumpers

Printed Circuit Board/
Flex/Rigid-Flex:
Standard PCBs
Flex ProductsType 3 Multi-Layer Flex

Rigid-Flex

PCB Backplane

Rigid-Flex

Rigid-Flex Products

Backplane Assemblies

Printed Electronics

RF Printed Circuit Boards
Circuit Card Assemblies

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RF & Microwave Interconnects:
Mil-Spec RF Connectors

Mil-Spec RF

Multiport High Density

Multiport HD Connectors
Quarterback Series
PTNC Series
BNC Series
TNC Series

Custom Designs
Quarterback Series

BNC Series

Backshell & Connector Accessories:
AS85049 Backshells

EMI/RFI Backshells

Band Lock Adapters

AS85049 Backshells

Environmental EMI/RFI Backshells

Micro-D EMI Backshell

Alumalight

Composite Backshells

Micro-D and Rectangular Backshells

Strain Reliefs

Dust Caps and Protection Caps

System Attachments:
P-Clamps & C-Clamps
P-Clamps & C-Clamps

Standoffs

Standoffs & Raceways
Cable Separators

Harness & Hat Supports
Fairlead Blocks

Jig Board Clamps

Hydraulic Pipe Supports
Fairlead Blocks

Cable Supports & Separators

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THE AMPHENOL ADVANTAGE

Amphenol Military & Aerospace Operations (AMAO) offers unique advantages that no otherinterconnect manufacturer can. The unique combination of interconnect expertise and harness
manufacturing capabilities enables us to offer the optimum solution at the design phase by leveraging
our connectors and wire management and harness solutions, with the goal of reducing weight,
installation and maintenance times, as well as optimizing cost.
Global footprint, local support:
With 21 divisions in North America, Europe, and Asia, we can provide a local, regional presence todesign and build any interconnect solution.
Cost-effective partnerships:
AMAO utilizes a vertically integrated supply chain to flow down the most competitive costs to ourcustomers, even on the most complex solutions.
Manufacturing versatility:
Many AMAO interconnect solutions have dual-production locations and off-set options (Mexico,
Estonia, India, and China) which means our customers benefit from low-cost options without the fearof a single-source position.
Technology proliferation from other Amphenol divisions:
As the 2nd largest interconnect company in the world, we’re highly diversified and can provide ourproven COTS technology from the antennas, sensors, industrial, and automotive markets to themilitary and aerospace world.
Amphenol Military & Aerospace Operations is perfectly aligned to provide the latest technologies,
cost-effective manufacturing and supply chain management, and local support to solve any military
and aerospace interconnect need.

Visit amphenolmao.com for more informationGLOBAL LOCATIONS

Amphenol Aerospace Operations
40-60 Delaware Avenue
Sidney, NY 13838
800-678-0141

Amphenol Griffith Enterprises
6000 East Coury Drive
Cottonwood, AZ 86326
928-634-3685

Amphenol Interconnect India
105, Bhosari Industrial Area
Pune – 411 026 India+91 20 27120363

Amphenol Commercial Air Division40-60 Delaware Avenue
Sidney, NY 13838
1-800-687-0141

Amphenol Canada
605 Milner Avenue
Toronto, ON Canada M1B 5X6
416-291-0647

Amphenol Japan, Ltd.
471-1, Deba, Ritto-City
Shiga, 520 3041 Japan+81 77 553 8501

Amphenol Nexus Technologies
50 Sunnyside Avenue
Stamford, CT 06902
203-327-7300

Amphenol Invotec
Unit 1-3, Hedging Lane Industrial Estate
Dosthill, Tamworth, B77 5HH United Kingdom+44 (0) 1827 263250

Amphenol Martec Limited
St. Augustines Business Park
Swalecliffe, Whitstable, Kent
CT5 2QJ United Kingdom+44 (0) 1227 793 733

Amphenol PCD
72 Cherry Hill Drive
Beverly, MA 01915
978-624-3400

Amphenol Ionix Systems
Prospect House, Taylor Business Park
Risley, Warrington, WA3 6HP United Kingdom+44 (0) 1942 685200

Amphenol SV Microwave
2400 Centrepark West Drive
West Palm Beach, FL
561-840-1800

Amphenol Limited
Thanet Way
Whitstable, Kent, CT5 3JF United Kingdom+44 (0) 1227 773200

Amphenol Times Microwave, Inc.
358 Hall Avenue
Wallingford, CT 06492
800-867-2629

Amphenol Socapex
948 Promenade De L’Arve – BP 29
74311 Thyez France+33 (0) 4 50 89 28 00

Amphenol Fiber Systems International
1300 Central Expressway North, Suite 100
Allen, TX 75013
214-547-2400

Amphenol Air LB SAS
2 Rue Clément Ader, Zac de Wé
08110 Carignan France+33 (0) 03 24 22 78 49

Amphenol Borisch Technologies
4511 East Paris AVEGrand Rapids, MI 49512
616-554-9820

Amphenol AirLB GmbHAm Kleinbahnhof 4D-66740 Saarlouis Germany+49 (0) 68 31/98 10 0

Amphenol Printed Circuit Board Technology
91 Northeastern Boulevard
Nashua, NH 03062
603-324-4500

Amphenol SEFEE
Z.I. des Cazes – BP243
12402 Saint-Affrique Cedex France+33 (0) 5 65 98 11 00

Amphenol Optimize
Carretera Internacional Km 6.5
Col. Parque Industrial
Nogales, Sonora, México. C.P. 84094+52 (631) 311-160
Amphenol Ionix Systems OÜ
Pikk Street 59b
Kuressaare 93815 Estonia+372 4521 780
AMAO – European Sales Operations
Via Barbaiana 520020 Lainate Milano, Italy+39 02 932 541
Amphenol Bar-Tec Ltd.
3 Hagavish st
POB 2479 Kfar-Saba 44641
Israel+972-9-7644100

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