Space and weight savings are mission-critical in today’s advanced military and aerospace platforms, where every gram and inch count toward performance, efficiency, and survivability. Xact EMS, an AS9100-certified and CMMC Level 2-compliant manufacturer, specializes in custom overmolded cable assemblies that deliver compact, lightweight, and high-performance interconnect solutions — engineered for the most demanding mission profiles.
Our overmolded military connectors combine rugged durability with space-efficient designs, offering high-density and lightweight solutions that reduce bulk without sacrificing reliability or performance. Using precision molding techniques, we create custom assemblies that meet tight spatial constraints while providing superior mechanical protection, environmental sealing, and EMI shielding — ensuring uninterrupted operation in combat and aerospace environments.
Key Advantages of Overmolded Assemblies from Xact EMS:
- Reduced Size & Weight – Streamlined profiles ideal for space-constrained applications such as UAVs, aircraft, and soldier-worn electronics.
- Enhanced Durability – Molded strain relief and robust housing for long-term reliability under extreme conditions.
- Superior EMI Shielding – Advanced materials and designs to prevent signal degradation in electronically noisy environments.
- Environmental Protection – Sealed against moisture, chemicals, dust, and temperature extremes to ensure field readiness.
- Customizable Form Factors – Tailored to meet unique design and performance requirements.
Military-Grade Connectors We Regularly Support:
- MIL-DTL-38999 – High-density circular connectors with advanced EMI shielding, trusted for aerospace, ground vehicles, and mission-critical communications.
- MIL-DTL-5015 – Rugged power and signal connectors designed for military vehicles, weapons systems, and heavy equipment.
- MIL-DTL-26482 – Compact, bayonet-style connectors ideal for avionics, unmanned systems, and portable tactical gear.
- MIL-DTL-83513 (Micro-D) – Ultra-compact, high-density connectors for UAVs, missile systems, and soldier-worn technologies.
- MIL-DTL-24308 (D-Sub) – Reliable data and signal connectors widely used in command and control, navigation, and communications equipment.
- MIL-DTL-83723 – Hybrid circular connectors built for high-vibration and high-temperature military and aerospace environments.
- ARINC 600 & 404 – Modular aerospace connectors supporting complex avionics, radar, and navigation systems.
- VG95234 – Reverse bayonet connectors for robust military communications and battlefield systems.
Applications Designed for Space-Constrained, High-Stakes Environments:
At Xact EMS, we provide rugged yet lightweight overmolded solutions engineered for:
- Next-generation fighter jets and rotary aircraft
- Compact soldier-worn communications and targeting systems
- Unmanned aerial vehicles (UAVs), drones, and autonomous defense platforms
- Missile guidance and high-speed munitions systems
- Battlefield networking and portable military electronics
- Vehicle-based C4ISR and advanced situational awareness systems
Why Xact EMS?
When your application demands lightweight, high-performance connectivity that stands up to the harshest operational environments, Xact EMS delivers precision-engineered overmolded assemblies that meet and exceed military and aerospace standards. Our team works closely with defense OEMs to design, prototype, and produce solutions that balance form, function, and survivability in the field.
Xact EMS — Your Partner for Compact, Rugged, and Mission-Ready Overmolded Interconnects.
