Not only has Air Electro been the premier and leading distributor of so many connectors and contacts to some of the world’s most influential and important companies for over 65 years, but we have also been the preferred source of custom connector and contact products.

Let’s explore the many custom products Air Electro produces…


Manufacturing

Manufacturing

Manufacturing

With over 60 years of experience in the Mil/Aero Connector Industry, Air Electro has evolved into an industry leader in the design and manufacturing of custom connectors and contacts.

Air Electro’s expertise in cylindrical and rectangular connectors with printed circuit contacts makes us the company of choice for custom applications. These products are available with integrated standoff and low profile shells, clinch nuts and helicoils for mounting. Epoxy sealed and EMI filtering is also available.

Our products are designed to applicable Military and customer specifications. Our Quality evaluation lab and engineering department utilize the latest equipment, analysis tools and computer-aided design software.

Capabilities Include:

  • Approved Manufacturer at a Variety of the World’s Largest Aerospace Companies.
  • Cylindrical and Rectangular Connectors designed for Printed Circuit Board applications.
  • Cylindrical Connectors Fully Compliant per MIL-DTL-38999, MIL-C-26482 & MIL-DTL-5015, MIL-DTL-26500, MIL-DTL-83723
  • Rectangular Connectors Fully Compliant per MIL-DTL-24308, ARINC 404 & 600
  • Meet or Exceed All Applicable Requirements of Military Specifications
  • All Insert Arrangements have been Designed to Allow for the Most Commonly Available and Widely Used Patterns
  • Standoff and Low Profile Shells, as well as Standoff Adapters
  • Helicoil and Clinch Nuts for Mounting
  • Right Angle PC Tail Contact available for Space Saving Measures
  • Epoxy Filled Connectors
  • High Amperage PC Tail Contacts
  • Low Profile Connectors with PC Tails
  • Offering NADCAP Approved Plating
  • FIlter Capabilities
  • Cable Assemblies
  • On-Site Engineers with Full CAD 3D capabilities
  • Quick Turnaround on Custom Quotes
  • Flexible Lead Times and Minimum Requirements

 


Connectors with Integrated Backshells

D38999 with Integrated Backshell

D38999-with-Integrated-Backshell-

For connector applications where weight reduction and increased shell-to-shell conductivity are paramount, turn to Air Electro’s line of connectors with integrated cable management features. Cable clamps, banding porches, shrink boot adaptors, and other widely used backshell configurations are integrated directly into the connector in lieu of accessory threads and user-installed accessories. Common styles are machined from a single piece of aluminum or stainless steel, and plated in accordance with Mil-Spec requirements. The result is a connector with exceptional electrical conductivity, a low profile rear end, and fewer components—and often at a lower total system cost compared to a traditional connector and backshell. Standard and custom designs are available with lead times as short as 6 weeks for first-runs.


Cylindrical Connectors with PC Tail Contacts

Cylindrical Connectors with PC Tail Contacts

Cylindrical Connectors with PC Tail Contacts

For applications where size, weight, and electrical performance are of paramount importance, connectors designed to mount directly to PC boards offer clear advantages over traditional “crimp and poke” contact terminations. Air Electro combines expertise in mil-spec I/O connectors and decades of experience designing and building custom PC tail contacts to provide turnkey PC tail connector solutions.

Air Electro’s PC tail connectors are based around common Mil-Spec connectors—including D38999, M28840, M83723, and M24308—and are intermateable with off-the-shelf plug connectors. However, they differ in their ability to mount directly onto a rigid, semi-rigid, or flexible PC board by means of special PC tail contacts. Contacts are offered in a variety of diameters, lengths, materials, and plating configurations to ensure a perfect fit with board-level hardware. Connector bodies are available in configurations optimized for use on electronics boxes. Styles include low profile box mount and jam nut receptacles, integrated PC board standoff feet, and traditional accessory threads—all of which are available with aluminum, stainless steel, and composite bodies.


Double Flange Connectors

Part #: AE38999/20WJ35SN-3

Part #: AE38999/20WJ35SN-3
Stand-Off Shell. PC Tail High Density. Stability for thin PC Tails. Helicoils loaded into shell for ease of assembly to board.

Double flange D38999 connectors enable users to securely install wall mount or jam nut connectors directly onto printed circuit boards without the use of flimsy standoffs or aftermarket adapters. Air Electro’s double flange connectors meet all applicable requirements of D38999 to ensure intermateability with qualified Mil-Spec plugs and feature a rugged one-piece machined shell that incorporates PCB standoff feet and mounting hardware. Connectors are available in standard and customized configurations, in a full range of Mil-Spec approved plating finishes, and can be supplied with a wide selection of PC tail contacts already installed.


Filtered Connectors

Filtered Connectors

Filtered Connectors

Air Electro offers a comprehensive selection of filtered Mil-Spec circular and rectangular connectors—including D38999, M24308 D-subminiature, M83723, and others—designed to protect sensitive electrical equipment from unwanted electromagnetic interference (EMI), radio-frequency interference (RFI), and transient voltage spikes.

Filtering can be accomplished by integrating capacitors, diodes, ceramic planar arrays—or any combination thereof—into a connector’s contacts to achieve the desired attenuation levels. Planar arrays are most commonly used, and provide a lightweight, low profile, and effective means of removing unwanted high-frequency noise from an electrical system. Diodes allow a connector to shunt spikes in voltage to the ground in the event of a surge, such as a lightning strike. Common filtering types include C, L-C, C-L, and Pi, selected based on the capacitance value desired. All types can be packaged inside inline, piggy-back, dual flange, or custom-designed shell configurations to meet the space requirements of every application.

In addition to filtered connectors, Air Electro can provide complete testing and burn-in services to ensure that parts perform as intended, as well as an expansive line of contacts, backshells, and accessories to satisfy all of your interconnect requirements.


Matched Impedance Contacts

Matched Impedance Contacts

Matched Impedance Contacts

Drawing from over 30 years’ experience in Mil-Spec contacts, Air Electro offers an expansive selection of qualified and bespoke matched impedance coaxial, twinax, and quadrax contacts. With operating frequencies ranging from megahertz to gigahertz, and styles including crimp, solder, and PC tail, Air Electro’s broad offering of shielded contacts are suited to mission-critical interconnect systems.

Qualified coaxial and concentric twinax contacts rated for use with common 50, 75, and 100 Ohm cables are available from stock. Differential twinax and quadrax contacts, designed to be direct replacements for common designs, are also available. Customized PC tail configurations are Air Electro’s specialty, offered either discretely or pre-installed into one of the many connector styles available in our portfolio. These work perfectly in conjunction with our PC tail connectors and PCB standoff adaptors.

We encourage you to bring us your next hard-to-solve matched impedance contact requirement—including connector style, contact size, operating frequency, and cable type.


PCB Standoff Adapters

PCB Standoff Adapters

PCB Standoff Adapters

PC board standoff adaptors allow standard Mil-Spec connectors with rear accessory threads to mount directly onto PC boards without the use of custom connector shells or flimsy spacers. Air Electro proudly offers standard and customized standoffs for D38999, M83723, MIL-DTL-5015, and other widely applied circular connector families that utilize rear accessory threads. Adaptors are available in all standard shell sizes and plating options—in aluminum, composite, and stainless steel—and in lengths suited to every PC board enclosure. Custom standoffs can be delivered in as quickly as 4 weeks, often with no minimum order quantity required.


PC Tail Contacts

PC Tail Contacts

PC tail contacts are an effective and streamlined way to marry connectors to PC boards, flex circuits, and other electrical equipment. However, due to the unique dimensional constraints of every system, no standard exists for PC tail contacts. For this reason, Air Electro designs and stocks an expansive selection of PC tail contact sizes, lengths, diameters, and configurations to support a wide breadth of applications.

All of our contacts meet or exceed the performance requirements outlined in AS39029, yet allow greater design flexibility than traditional “crimp and poke” Mil-Spec contact termination. Custom designs are also available, with flexible minimum order quantity and first-run turnaround time can be as fast as 6 weeks.

We welcome challenging and unusual configurations, including specialty metals, thermocouple, selective or extended-durability plating, and 45° and 90° PC tails. For those seeking impedance matched terminations, Air Electro offers coaxial, twinax, triax, and quadrax contacts with PC tails in standard and custom configurations—designed to intermate with AS39029 and other industry-standard items.

In addition to discrete PC tail contacts, we proudly offer turnkey pre-terminated PCB connectors ready to mount directly onto your board. Popular styles include connectors with integrated PC board standoffs and pre-installed solder-dipped PC tail contacts. Air Electro looks forward to supporting your most challenging PC board interconnect requirements.


Sealed Connectors

Sealed Connectors

Sealed Connectors

For mission-critical applications that call for lightweight, highly environmental-resistant I/O connections, call on Air Electro’s line of sealed connectors. Epoxy-sealed connectors offer outstanding moisture and gas ingress protection and are an excellent alternative to glass-to-metal sealed hermetics, whose weight, expense, and long lead times often make them unsuitable for certain applications.

Air Electro offers a broad range of standard connector families—including D38999, M24308, M26500, M83723, and others—that can be tailored to each application’s temperature, sealing, and electrical requirements. Available shell options include integrated PC board standoffs, low profile, standard accessory mounts, and integrated backshells. Connectors can be supplied pre-wired (pigtails) or with PC tails, and are available with standard M39029 type signal contacts as well as high frequency-matched impedance coax, twinax, and quadrax contacts.

Sealed Connectors

What’s more, Air Electro can design, build, and test custom configurations to meet the most challenging size and performance requirements. We encourage you to use our 20+ years of manufacturing experience to find the right solution for your sealed connector needs.


Thermocouple Contacts

Thermocouple Contacts

Thermocouple Contacts

Air Electro offers a comprehensive selection of M39029 and custom thermocouple contacts for use in mission-critical applications. Many qualified versions are readily available from stock, and have no minimum order quantity. We also offer uncommon and difficult to find versions of Mil-Spec thermocouple contacts. Common configurations include Type K (Alumel-Chromel), Type J (Iron-Constantan), and Type T (Copper-Constantan). In addition, Air Electro is well equipped to design and build custom thermocouple contacts in configurations that fall outside M39029, including PC tail, wire wrap, first-mate last-break, and specialty metals, such as Nicrosil and Nisil (Type N).


AEI Manufacturing Press-Fit Contacts

AEI Manufacturing (an Air Electro company) Press-Fit Contacts

AEI Manufacturing Press-Fit Contacts

AEI Manufacturing Press-Fit Contacts

Air Electro is a world leader in commercial, military and industrial connectors and contacts. We manufacture the most comprehensive MIL-DTL-38999 Series I, II, and III Press-Fit compliant pin contacts for PCB mount or solderless applications. Compliant pin connectors are originally designed for ease assembly and to decrease the number of fluctuations during the soldering process. Air Electro has taken this technology and applied it to the commercial and military aviation to design the most unique, custom and cost-effective compliant Press—Fit tail connectors.

Our Press-Fit contacts are most often used in all the variations of the mil type connectors, including MIL-DT38999, MIL-DTL-83723, MIL-C-5015 and MIL-DTL-26482, among others.

Our pin contacts are removable using standard military ins./ext. tools.

Air Electro Press-Fit technology:

  • Contact finish: gold over nickel plate.
  • Contact material: suitable copper alloy.
  • Shell material: aluminum alloy.

Press-Fit technology has several advantages over SMT technology, such as:

  • Environmentally friendly
  • No thermal stress on PCB or connector.
  • Avoid solder defects such as bridges, open, etc.
  • Fast and simple assembly process
  • The process requires less floor space
  • The lead-free operation that does not require costly “hi-temp” plastics.
  • Higher pin-count per area for high pin count
  • Easy and repeatable
  • No need to use flux, heat, cleaning and defects of copper dissolution or IMC.

Air Electro has been your Custom Product solution for over 65 years.  If you are ready to explore our enormous inventory, place your order, or ask questions, visit our Custom Products page on our website now.

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