Six Months of Innovation with AirBorn and Molex

As we actively build and reinforce relationships, we are discovering some value-added solutions among Molex’s extensive product portfolio. For example, Molex’s FCT D-Sub Connectors are time-tested, field-proven D-subminiature solutions that are used in a diverse range of applications, including industrial automation, MedTech, commercial aviation and telecommunications. As these products prioritize reliability, ruggedness and signal integrity, they also are ideal for aerospace and defense applications, including a few minor design modifications for MIL-SPEC qualification.

Busbars from Molex may also play a bigger role in serving as the backbone of electrical power distribution for a vast range of aerospace and defense applications—from aircraft and vehicles, power distribution systems and avionics to military equipment and high-power spacecraft. To that end, we are looking closely at Molex’s existing busbar and high-speed connectors, some of which can be customized slightly to meet stringent military specifications.

It is important to realize that our combined strength is not just about expanding the product portfolio. The overarching objective is to facilitate deeper partnerships through customer value creation as we deliver differentiated capabilities. That is why we are eager to work with BittWare, a Molex company and leading supplier of enterprise-class accelerators and Field-Programmable Gate Array (FPGA) cards that perform massive numbers of operations simultaneously. This makes them particularly useful for embedded computing systems that demand real-time data processing, such as flight control and navigation, sensor fusion, image and video processing, as well as radar and electronic warfare. 

Not only can BittWare benefit from partnering with AirBorn as we engage our aerospace and defense customers, they also can leverage AirBorn’s longstanding involvement with VITA (VMEbus International Trade Association) to align strategically with various VITA working groups. In essence, both AirBorn and BittWare are primed to contribute to the overall VITA ecosystem by creating and promoting compliant solutions for advanced embedded systems found in critical aerospace and defense applications.

Another important strategy for driving customer value is our longstanding practice of soliciting input through regular “voice of the customer” initiatives, which enable us to better anticipate and react to rapidly growing technology requirements. AirBorn’s SInergy mini-modular hybrid connector family is a case in point. It originated from consistent and productive customer interactions. 

Early in the product development cycle, 50 customers were asked to articulate their future connector needs. They responded with a preference for modular solutions that could be used for either signal power or RF. Also desired was the ability to combine several inputs into a single connector for ultimate flexibility. The result is an award-winning line of small form-factor connectors designed to deliver up to 25Gpbs per lane with military-grade resilience, making SInergy an ideal choice for a host of applications, including military heads-up display helmets.  

We also are collaborating with customers and colleagues on how best to leverage Molex’s extensive experience in optical connectivity. This is another excellent example of a technology that is becoming increasingly vital for aerospace and defense applications, especially given escalating demands for high-speed data, security and reduced size, weight, power and cost (SWAP-C). 

Of course, we are looking closely at electrification trends in military land systems, along with the growing need for autonomous and connected vehicles. For decades, Molex’s automotive innovations have been elevated by a legacy of producing power, signal and connectivity solutions to form the central nervous system of next-generation vehicle architectures. 

Specifically, Molex has been at the forefront of addressing the shift to electric vehicles (EVs) while embracing new vehicle architectures that need to support sensors, multiple cameras, radar, LiDAR and other technologies. As an early proponent of zonal architecture, Molex has prioritized the role of hybrid or mixed connectors needed to handle the power and high-speed signals associated with in-vehicle networks that will drive next-gen EVs.

This means that AirBorn does not have to reinvent the wheel for every military land system challenge. We can combine AirBorn’s MIL-STD test methods and requirements with Molex’s proven automotive capabilities to support an emerging breed of military land systems, such as the XM-30 Mechanized Infantry Combat Vehicle. This collective understanding will fuel the development and delivery of innovations that will accelerate fundamental shifts in military vehicle design, including electrification, autonomy and open architectures.

Foundational to the next chapter in our integration journey is determining where, when and how AirBorn can take advantage of Molex’s global manufacturing footprint and focus on automation. We are exploring opportunities worldwide to elevate product quality and consistency while increasing our ability to ship products faster and closer to aerospace and defense customers.

As a leader in advanced manufacturing, including industrial automation and robotics, Molex employs highly precise and repeatable manufacturing processes for connectors, cable assemblies and power supplies. This level of consistency is crucial for aerospace and defense applications where miniaturized and high-density products are essential. Molex’s global footprint, manufacturing automation and operational excellence help ensure that together we can deliver more reliable, higher-quality, cost-effective and more rapidly available solutions to our customers. 

For instance, AirBorn’s M (Micro-D) and R (Rectangular PCB Connectors) series are known for their reliability in the most demanding aerospace and defense applications. These connectors often feature very small pitch sizes, high pin counts and tight tolerances, making them ideally suited for robotic assembly and automated in-plating.

In addition to moving forward with these programs, we are exploring how automation can improve the coplanarity of contacts for surface-mount connectors to ensure reliable solder joints and mechanical stability. Molex’s expertise in precision component placement will ensure that connectors are placed exactly where they need to be on the Printed Circuit Board (PCB). Precise control through automation of these types of processes directly impacts the quality, efficiency and cost-effectiveness of our manufacturing operations.

I am pleased to report that the AirBorn team is on track to complete these first three automation programs by the end of 2025, which is less than half the time it would have taken to develop and deploy them without the benefit of our shared expertise.

Looking ahead, we plan to infuse automation and operational excellence wherever possible to continually strengthen our position as a single, trusted supplier of complete systems, simplifying overall product design, procurement and integration. To accomplish that, we intend to build on the natural momentum that occurs every time AirBorn and Molex engineers meet. Not only will this empower us to unite our complementary skills, scale and scope quickly and effectively, it will enable us to establish stronger relationships, broaden our capabilities and deliver the most innovative solutions for tackling aerospace and defense customers’ toughest challenges—one value-added solution at a time.