Analysis of Difficulties in Improving the Quality of Domestic Aero-Electric Connectors

Aero-Electric (affiliated with Conesys) has long been committed to high-reliability military-grade connector products, covering standards such as MIL-DTL-38999 Series I/II/III, MIL-DTL-5015 (post-release version), MIL-DTL-83723, and MIL-DTL-26482. These products are widely used in harsh environments with high vibration, high temperature, and corrosion resistance, and adopt a vertically integrated production process with CNC machining, precise plating, injection/molding, and assembly control. It is supported by a reliable quality system. These advanced technologies and strict standards have set a high-quality target for domestic connectors and also require multiple technical challenges to be addressed in the pursuit of domestic development.

Main technical difficulties in improving the quality of domestically produced connectors
Precision technology and consistency control of standards
● Die and structural accuracy: Aero-Electric connector has very high geometric accuracy requirements for the shell, pin, thread, seal and other parts. To replace it, domestic products must have high-precision CNC machining and injection molding capabilities.
●Standard compatibility and interchangeability: For example, the Bayonet lock mechanism of the MIL-DTL-38999 series, or the threaded fastening method of MIL-DTL-5015, all need to ensure that the domestic structural methods are completely compatible with imported parts, guaranteeing interchangeability.
Materials and Surface Treatment
Shell corrosion resistance treatment: Aero-Electric often uses electroplated nickel, aluminum magnesium alloy, chrome oxide, and other corrosion-resistant shell coatings. Domestic products need to be accurately replicated or optimized to pass salt spray and corrosion tests.
Contact piece coating: Metal electrical contact pieces mostly use gold plating and copper alloy materials to maintain low contact resistance and wear and corrosion resistance, which is a difficult point for domestic improvement.
Environmental reliability verification
● High temperature, vibration, and humidity test capabilities: The MIL-DTL series is widely used in extreme temperature conditions (from -55 °C to +200 °C), high vibration, etc. Domestic products require the construction of a complete set of environmental laboratory equipment to implement reliability tests.
●Insertion/extraction life and sealing: Aero-Electric products such as MIL-DTL-26482 Series II can meet more than 500 insertion/extraction and waterproofing and dustproofing requirements, while domestic products need to ensure product consistency and life standard.
Quality Control and Certification Qualifications
Quality system construction: Aero-Electric establishes a strict quality traceability system based on certifications such as ISO 9001 and AS9100, and domestic suppliers need to build and maintain corresponding systems.
●Third-party verification support: High-reliability products usually require third-party inspection reports, such as protection level, mechanical properties, electrical properties, etc., and domestic products need to establish a stable verification mechanism.
Production scale and process stability
● Mass production consistency: The mature batch production experience of imported factories can ensure shipment consistency, while domestic production needs to ensure "defect-free consistency" in mass delivery while improving quality.

Process stability and cost balance: Improving quality cannot ignore costs. Domestic products need to enhance process stability and quality pass rate on the basis of controlling costs.

In the comparison with the Aero-Electric benchmark, domestic connectors need to break through multiple technical difficulties in structural accuracy, material processing, environmental reliability testing, quality system construction, and production consistency. This not only requires advanced equipment and process capabilities to support it but also requires systematic production and continuous improvement. Only by truly achieving these technological breakthroughs can we build truly competitive domestic high-reliability military specification connectors and achieve the goals of supply-side optimization and domestic substitution.
If you are interested in the domestic substitute products of Aero-Electric brand connectors, or have procurement needs, or have relevant production or sales channels, and wish to cooperate or communicate in-depth, please contact us through the following methods:Manager Zhang (18665383950, same WeChat number)Look forward to working together with more industry partners!