Military-Grade Aviation Connectors & Aerospace Electrical Components
ABC Aviation specializes in manufacturing military-grade aviation connectors designed to meet the most demanding requirements of modern Aircraft Electrical Systems. Our comprehensive product range includes J599 series connectors, CX-16 military connectors, and specialized Aviation Socket and holder assemblies that deliver unparalleled reliability in extreme aerospace environments.
As a leading supplier of High-Performance Connectors for both commercial and military aviation, we understand that every connection must withstand vibration, extreme temperatures, moisture, and electromagnetic interference. Our aviation connectors are engineered with precision to ensure:
Y11P-2041ZK10 Series
Application: Avionics & Instrumentation Systems
Configuration: Multi-pin circular connector
Features: Environmental sealing, quick-disconnect
Compliance: Military specifications for aviation use
J599 Series Connectors
Application: High-density power & signal
Models: 26KF32PA-H, 26WH35SN variants
Features: Bayonet coupling, rear release contacts
Rating: Up to 500V, various current ratings
CX-16 Military Connector
Application: Military aircraft systems
Configurations: 3P, 5P, 7P, 10P options
Features: Hermetically sealed, EMI shielded
Environment: Extreme temperature & vibration
Our aviation grade connectors are manufactured with strict adherence to military connector specifications, ensuring compatibility with existing aircraft systems while providing enhanced performance and durability. Whether you need 2 pin aviation connectors for simple circuits or complex 16P multi-pin connectors for sophisticated avionics, ABC Aviation delivers solutions that exceed expectations.
Technical Specifications & Performance Data
Detailed technical specifications for our core Aviation Connector series. All products are designed and tested to meet or exceed relevant aerospace standards.
| Product Series | Contact Configurations | Voltage Rating | Current Rating | Temperature Range | Environmental Protection |
|---|---|---|---|---|---|
| J599 Series (26KF32PA-H, 26WH35SN) | 32, 35, 55 contacts Various insert arrangements | Up to 500V RMS | 7.5A - 23A per contact Power contacts: 40A | -65°C to +175°C Intermittent: +200°C | IP67 standard Corrosion resistant finish |
| CX-16 Military Series | 3, 5, 7, 10 pin configurations Standard & reverse gender | 600V AC/DC | 13A continuous 20A intermittent | -65°C to +200°C (per MIL-DTL-38999) | Hermetic sealing EMI/RFI shielding |
| Y11P-2041ZK10 Series | Multiple pin counts Custom arrangements available | 250V AC/DC | 5A signal contacts Power contacts: 20A | -55°C to +125°C Operating temperature | Environmental sealing Vibration resistant |
| YB Series (YB2TAX, YB3TAX) | 2-8 pin configurations Standard aviation layouts | 250V AC/DC | 10A continuous 15A peak | -55°C to +105°C | Moisture resistant Dust proof design |
Additional Electrical & Mechanical Specifications
- Contact Resistance: <5mΩ per mated pair (initial)
- Insulation Resistance: >5000MΩ at 500V DC
- Dielectric Withstanding Voltage: 1500V RMS at sea level
- Vibration Resistance: 10-2000Hz, 15G (MIL-STD-202)
- Shock Resistance: 50G, 11ms duration
- Durability: 500+ mating cycles minimum
- Cable Retention: >50 lbs pull-out force
Product Gallery: Military Aviation Connectors
Visual documentation of our military aviation connector product lines, showcasing construction quality, design features, and standard configurations.
J599 Series 26KF32PA-H
High-density circular connector with bayonet coupling mechanism, ideal for avionics and instrumentation applications.
J599 26WH35SN Military Connector
Military-spec connector with environmental sealing, rear-release contacts, and EMI shielding capabilities.
JY27473T16B06SN 16-Pin Connector
16-contact aviation connector with socket assembly, designed for complex wiring harnesses in aircraft systems.
CX-16 Military Connector Series
Hermetically sealed military connectors available in 3, 5, 7, and 10-pin configurations for extreme environments.
Additional technical images, cross-sectional views, and installation diagrams available upon request. Contact our technical support team for specific visualization needs.
Engineering Features & Competitive Advantages
Our aviation connectors with military grade quality incorporate advanced engineering features that deliver superior performance, reliability, and longevity in demanding aerospace applications.
Superior Environmental Sealing
Multi-stage sealing systems utilizing silicone rubber, fluorosilicone, or PTFE gaskets provide complete protection against moisture, dust, and fluids. Our CX-16 military connectors feature true hermetic sealing for applications requiring absolute environmental isolation.
Enhanced EMI/RFI Shielding
Advanced shielding designs with 360° continuous metal-to-metal contact provide >100dB attenuation from 100MHz to 10GHz. Essential for sensitive avionics and communication systems where electromagnetic compatibility is critical.
Vibration & Shock Resistance
Patented contact retention systems and robust shell designs withstand severe vibration (15G) and shock (50G) per MIL-STD-202 and MIL-STD-810. This prevents contact fretting and maintains electrical continuity in turbulent conditions.
Quick-Disconnect Coupling
Bayonet (J599 series) or threaded (CX series) coupling mechanisms allow for rapid mating and unmating without special tools. Visual and tactile indicators ensure proper connection and prevent incomplete mating.
Why Choose ABC Aviation Connectors?
- Full Compliance: Manufactured to meet or exceed MIL-DTL-38999, MIL-DTL-26482, MIL-DTL-5015, and other relevant military specifications
- Proven Reliability: Thousands of units deployed in commercial and military aircraft with documented field performance
- Technical Support: Direct access to our application engineering team for connector selection and integration guidance
- Competitive Pricing: Military-grade quality at commercial-competitive prices through efficient manufacturing processes
- Global Supply Chain: Reliable delivery to aviation hubs worldwide with full certification documentation
Application Guidelines & Installation Process
Proper selection, installation, and maintenance are critical for optimal performance of aviation grade connectors. Follow these guidelines for successful system integration.
5-Step Selection & Installation Methodology
Application Analysis & Connector Selection
Determine your specific requirements:
- Electrical Parameters: Voltage, current, signal types (power, data, mixed)
- Environmental Conditions: Temperature range, altitude, moisture, chemicals
- Mechanical Requirements: Vibration levels, mating cycles, space constraints
- Standards Compliance: Required military or commercial specifications
Our technical team can assist with appropriate aviation connector selection.
Cable Preparation & Contact Assembly
Proper cable termination is essential:
- Strip cable to specified length using calibrated tools
- Select appropriate aviation grade terminals (crimp, solder, or insulation displacement)
- Use calibrated crimping tools with proper die sets
- For aviation connector soldering, use temperature-controlled irons and approved solder
- Perform pull-test verification on sample terminations
Connector Assembly & Sealing
Assembly procedures for reliable connections:
- Insert contacts into proper cavities following wiring diagram
- Ensure positive contact retention (audible click)
- Install appropriate backshells and strain relief
- Apply sealing compounds or gaskets as specified
- Torque coupling nuts to specified values using calibrated tools
Testing & Verification
Comprehensive testing before installation:
- Continuity test: Verify all circuits from connector to cable end
- Insulation resistance: >500MΩ at 500V DC
- Hi-pot test: 1500V AC for 60 seconds (sampled or 100%)
- Visual inspection under 10x magnification
- Environmental testing for critical applications
Installation & System Integration
Final installation in aircraft systems:
- Route cables with proper bend radius and strain relief
- Secure connectors with appropriate mounting hardware
- Maintain minimum clearance from heat sources and moving parts
- Mate connectors ensuring proper alignment and full engagement
- Document installation with photographs and test records
Application Scenarios & Aircraft Systems
ABC military aviation connectors are deployed in critical aircraft systems where reliability directly impacts safety and mission success.
Avionics & Flight Control Systems
Our J599 series connectors provide reliable interconnections for flight computers, navigation systems, autopilots, and instrument panels where signal integrity is paramount.
- AS9100 Rev D Certified: Aerospace quality management system certification
- ISO 9001:2015: Quality management system standard
- Military Specifications Compliance:
- MIL-DTL-38999 Series I, II, III, IV: Circular connectors
- MIL-DTL-26482: General purpose circular connectors
- MIL-DTL-5015: Heavy duty circular connectors
- MIL-STD-810G: Environmental engineering considerations
