Connector Insights from iCONN

What Is Low-Pressure Overmolding? | iCONN Systems

efreemon@iconnsystems.com (Evan Freemon) — Wed, 27 May 2026 04:43:36 GMT

Overmolding is a common method for protecting electronic assemblies, adding a molded thermoplastic or elastomer layer for sealing, strain relief, and mechanical protection.

In high-pressure processes, however, that same protection can come at the cost of component damage. Low-pressure overmolding addresses this by encapsulating assemblies without introducing excessive mechanical or thermal stress.

iCONN Systems applies this process to custom cable assemblies and connectors designed for harsh environment applications.

What Is Low-Pressure Overmolding and Why Does it Matter?

Low-pressure overmolding encapsulates electronic components using low-viscosity thermoplastic adhesives, typically polyamides. These materials flow easily at reduced injection pressures, allowing complete mold fill without damaging sensitive assemblies.

Typical processing conditions include lower pressures and temperatures compared to conventional injection molding, reducing mechanical and thermal stress on components. Short cycle times further minimize exposure during processing.

During the process, components are placed into a pre-designed mold. The thermoplastic adhesive is heated to a flowable state and injected into the mold cavity, where it surrounds and encapsulates the assembly. The material then cools and solidifies before the part is removed for downstream processing.

Low-pressure overmolding is often evaluated as an alternative to traditional potting and encapsulation. In potting, assemblies are enclosed in a housing and filled with resin, which cures into a rigid structure.

While effective for sealing, potting creates a permanent enclosure that limits rework and can introduce stress at cable exit points. In contrast, overmolding provides integrated strain relief and a more flexible protective layer.

Benefits of Choosing Low-Pressure Overmolding vs. Traditional Potting and Encapsulation

More and more manufacturers are choosing low-pressure overmolding as a protective shielding technique that's less aggressive on the assemblies and less irreparable than potting and resin encapsulation.

In practice, this approach offers several advantages over potting and encapsulation:

Environmental sealing against moisture and contaminants
Integrated strain relief that reduces stress on cables and connectors
Resistance to vibration and mechanical shock
Lower material usage compared to full encapsulation (application-dependent)
Improved manufacturability and cycle efficiency

Low-pressure overmolding is commonly used in applications such as:

Cable assemblies and wire harnesses
Sensors and sealed electronic connectors
Printed circuit board (PCB) protection
Harsh environment interconnect systems

iCONN Can Help Ruggedize Your Next Electronics Assemblies

iCONN Systems provides custom cable assemblies, connectors, and overmolded solutions designed for demanding environments. Our engineering team supports design, prototyping, and production, ensuring each assembly meets application-specific performance requirements.

Our capabilities include overmolded cable assemblies and sealed electronic connectors built to perform in harsh conditions. Manufacturing processes align with ISO 9001:2015 quality standards and applicable environmental regulations such as RoHS and REACH.

Contact our team to review your application requirements, discuss design constraints, or request a quote for your next overmolded assembly.

M8 Connectors vs. M12 Connectors: How They Compare | iCONN Systems

efreemon@iconnsystems.com (Evan Freemon) — Wed, 28 Aug 2024 17:44:49 GMT

Having the right components in place is essential for getting a job done, and with many connector types available it’s important to know the distinctions between the various options.

When it comes to M12 vs. M8 connectors, there are certainly many overlapping attributes, but there are also some key differences. Let’s take a look at how M8 and M12 connectors differ, how they are utilized, best practices for operation, and everything that iCONN Systems can provide for your operations.

What Is the Difference Between M8 and M12 Connectors?

M12 and M8 connectors facilitate the transfer of data in a system, so ensuring use of the correct connector is key for the proper transfer of information.

M12 connectors utilize a 12 mm threaded, circular head that delivers a robust, but flexible, connection to a variety of other types of equipment. Developed for application in environments that lead to corrosion, the design of M12 connectors inhibits such issues. Settings that necessitate significant data transfer rates are also prime uses of M12 connectors. These connectors often feature 2, 3, 4, 5, 6, 8, 12, or 17 pins to fit accompanying holes.

M8 connectors, meanwhile, feature an 8 mm circular head and are often employed in many industrial settings. Their use overlaps with M12 connectors in many ways, but because of their smaller footprint, via the 8 mm housing, they may be more preferable in some cases. These connectors often feature 3, 4, 5, 6, or 8 pins to fit accompanying holes. Male and female and straight and angled options are available.

Applications: What Are M8 Connectors Used For?

M8 connectors are primarily utilized within industrial automated systems, where they link actuators, sensors, switches, and other components. Settings that necessitate a lightweight connector or those with minimal space are ideal candidates for M8 connectors, which is one of the reasons they are often employed in projects within the automotive field.

Other notable industries that use M8 connectors include HVAC, textile and printing, food and beverage processing, machine building, rubber and plastics, and many more.

Applications: What Are M12 Connectors Used For?

As noted above, M12 connectors were designed for utilization in corrosive environments, and also help in applications that require significant data transfer. Often used within industrial automation settings, these connectors are put to use in applications relating to actuators, sensors, Profibus, Fieldbus, industrial Ethernet, and more.

Due to their rugged construction, dependability, and small size, M12 connectors are particularly prized within the industry, being high among the most utilized components.

Size and Design: M8 vs. M12 Connectors

As industry veterans are aware, the “M” of these connectors’ names indicates “metric,” with the accompanying number describing the connector head’s diameter size in millimeters.

The M12 connector has become something of a classic within the field, with its popularity leading to the development of varied pin structures to facilitate diverse applications. M8 connectors, meanwhile, are known for their resistance to shock, vibration, and moisture, making them the connectors of choice in harsh environments that would pose significant problems for other types.

M8 and M12 Connector Coding Designations

Coding for M8 and M12 connectors is broken down into the classifications of A, B, C, D, and X. “A Coded” connectors feature a variable number of pins and are usually employed in lower-power settings. Due to its ubiquity and ease of use, A Coding is the default. “B Coded” connectors, meanwhile, are utilized for network cables for Fieldbus applications.

“C Coded” connectors are not as common as their A and B counterparts, but are used with AC sensors and actuators. “D Coded” connectors are utilized within Ethernet and ProfiNet systems, transferring data up to 100 megabytes. Lastly, “X Coded” connectors are a newer development within the space, being able to facilitate the transfer of data in the gigabyte range.

M8 vs. M12: Choosing the Right Connector from iCONN Systems

iCONN Systems provides M8 connector and M12 connector options via our iSENSOR i8 series and our iSENSOR i12 series.

Our i8 series features:

Straight and right-angle overmolded plug options
Rear- and front-mount panel mount receptacles
A, B, and D code options
Nickle-plated brass, stainless-steel, or PVC components
Snap lock or threaded couplings
IP67 ingress protections
Voltage rating up to 300V
Amperage rating up to 7.5A

Our i12 series features:

Straight and right-angle overmolded plug options
Front-mount panel mount receptacles
A, B, and C code options
Nickle-plated brass or stainless-steel components
Threaded couplings
IP67/IP69K ingress protection
Voltage rating up to 300V
Amperage rating up to 7.5A

Along with all of this, our team is adept at creating custom connectors as well, so if your project requires a specialized component, be sure to reach out to us so we can assess your needs and deliver the ideal part.

Deciding Between M12 vs. M8 Connectors for Your Project? Let Us Help!

If you have a project that could utilize M12 or M8 connectors but you’re unsure of which option would provide the most benefit in your specific case, contact our expert team. We look forward to assisting you.

How to Crimp Electrical Connectors

RmRegole@iconnsystems.com (Rick Regole) — Wed, 03 Jul 2024 15:12:05 GMT

Electrical connectors are a type of hardware that affixes to a receptacle to complete an electrical circuit and deliver electricity to a piece of equipment. This connection can be between two wires or a wire to a terminal. Crimping is a process used to join wire to wire or wire to terminal. Just as the name suggests, bonding occurs when one piece of metal is deformed and compressed tightly with another piece of metal. This process does not require any soldering, and involves the following steps and equipment:

Choosing the Right Equipment

You will need a specialized crimping tool. They can look similar to pliers or ratchets. Ratchet crimping tools are typically recommended over plier tools because they produce a more reliable crimp. In either case, crimpers are not one-size-fits-all. There are dozens of variations in shape and mechanical performance. The crimping tool you select will depend on the type and size of the terminal you are affixing. You will also need:

High-quality crimp terminals: the electrical connection in which you will insert the wire.
Stranded wire (not solid core): a metal wire comprised of several smaller wires.
Heatshrink Tubing: a plastic tube used to insulate the joint between the electrical connector and the wire.
Wire strippers: a small tool that removes a portion of the insulation on the outside of an electrical wire.

Crimping Electrical Connectors

Strip the Wire: Use the stripping tool to strip the end of the stranded wire, being careful not to damage the conductors. The packaging of the crimp terminals may indicate how much of the wire needs to be stripped.
Insert the Wire: Insert the stripped wire inside the crimp terminal and place both pieces into the crimping tool. Sometimes it’s easier to put the crimp terminal into the tool first and insert the wire after. Check to make sure the wiring and terminal are properly aligned.
Crimp the Wire and Terminal: If using a ratchet, cycle the tool until it releases. If using a plier, you may need to crimp terminals twice (the conductor end first and the insulation second), potentially with different settings to make a secure bond.
Inspect the Bond: Remove the wire and crimp terminal from the tool and assess the crimp to ensure both pieces gripped together properly. A small tug should do the trick.
Heatshrink the Joint: Slide the tubing over the joint and (if necessary) use a heat gun to shrink the plastic, encapsulating the newly-crimped connection. Be sure to check that the sleeving is not interfering with the terminal end of the crimp.

When it comes to electrical wiring, a lot can go wrong. Your safest and most cost-effective choice is to purchase crimped electrical connectors off-the-shelf or custom-designed through a reliable OEM like iCONN Systems. We offer a large selection of electrical connectors and specialize in custom-designed connectors that stand up to even the most extreme applications.

Shielded Cable: Foil Shielding vs. Braided Shielding in Cable Assemblies

efreemon@iconnsystems.com (Evan Freemon) — Wed, 03 Jul 2024 15:03:38 GMT

A top concern for shielded cable assemblies involved in the transmission of data are electromagnetic and radio-frequency interference (EMI/RFI). The slightest disturbance could decrease signal quality, cause data loss, or completely disrupt the signal, resulting in equipment failure.

Shielded cable assemblies feature shielding, which is a layer of insulation (containing electrical energy) that is wrapped around an electrical cable to prevent the cable from emitting or absorbing EMI/RFI. iCONN Systems specializes in various types of shielding, but the most commonly used methods include “foil shielding” and “braided shielding.” Here is a direct comparison of foil shield vs. braided shield to help you decide which is best for your product. Keep in mind, when you partner with iCONN, we will help guide you on every detail of your shielded cable assembly construction to ensure the right fit for your application.

Types of Shielded Cable:

Foil Shielding

Foil shielding is a type of shielded cable that encases a cable using a thin layer of copper or aluminum with a polyester backing that increases durability. Foil shield works in tandem with a tinned copper drain wire to ground the shield.

Advantages of Foil Shielding

Foil shielding offers 100% coverage and can stand up to high-frequency RFI applications. Because foil shield is lightweight and inexpensive, it’s also quick, cheap and easy to produce.

Disadvantages of Foil Shielding

Despite foil shielding’s coverage and protection against RFI, it’s not very durable and its elements are fragile. These attributes give foil shielding a poor flex life and virtually no mechanical strength, which makes it difficult to work with. We do not recommend foil shielding for high-flex applications.

Braided Shielding

Braided shielding is a type of shielded cable that uses a tightly woven lattice of thin tin or copper wires to encapsulate a shielded cable assembly. The formation looks like a braid and provides a low-resistance path to ground.

Advantages of Braided Shielding

Braided shield is the most “traditional” form of shielding and offers greater versatility than foil shielding. This type of shielding is as strong as it is flexible, offering plenty of flex life and mechanical strength. While braided shielding does work at all frequency types and performs best at low frequency, iCONN recommends it for EMI applications in low to medium frequencies.

Disadvantages of Braided Shielding

Braided shield does not guarantee 100% coverage. However, it does offer 70% to 95% coverage. The degree of coverage will depend on how tight the branded formation is woven. Braided shielding is also bulky, which means it may not be suitable for micro-products or tight spaces. Because of the size and weight of braided shielding, it also tends to cost more and requires more time to produce. Finally, braided shielding isn’t as easy as foil shielding to terminate.

Cable Shielding: The Pros and Cons

Choosing which type of EMI shielding isn’t always easy to identify. Luckily, there are pros and cons to each type that can help you decipher which one is best for your application environment.

Braided shielding has excellent mechanical strength and is best for low to medium frequencies, while foil shielding is great for high frequency applications. Braided can be more expensive and difficult to produce, and foil is inexpensive and easier to produce. The most traditional form of shielding, braided shielding only provides 70-90 percent coverage, while foil shielding provides 100 percent.

One of the many benefits of partnering with an interconnects expert like iCONN Systems is the practical knowledge we share with you on topics like shielded cable. For example, did you know you can have the best of both shielding options in one product? iCONN produces hybrid foil/braided shielding that blends all the benefits of both configurations to counteract many of the disadvantages. Learn more about EMI/RFI shielding and download our whitepaper today!

The IP Ratings Chart | How to Understand IP Ratings

efreemon@iconnsystems.com (Evan Freemon) — Fri, 24 Feb 2023 22:02:57 GMT

An Ingress Protection (IP) rating is a measure of the degree of protection provided by an electrical connector against the ingress of solid particles and water. The ingress of solid particles and water can cause damage to equipment, potentially leading to malfunction or failure. By selecting electrical equipment with the appropriate IP rating or ‘code,’ you can ensure the equipment is able to withstand the conditions in which it will be used, minimizing the risk of damage or failure.

How IP Ratings Work

The IP rating system uses two numbers to indicate the level of protection provided by an electrical connector or other piece of equipment against the ingress of solid particles and water. Sometimes, a letter will follow the numerical code to indicate additional information about the product. IP codes are determined using standardized test methods. The International Electrotechnical Commission's (IEC) standard 60529, Degrees of Protection Provided by Enclosures (IP Code), provides detailed guidelines for testing and rating the protection provided by enclosures against the ingress of solid particles and water.

IP Ratings Chart

First Digit (Range: 0-6)	Signifies Protection Against Solid Particles	Second Digit (Range: 0-9)	Signifies Protection Against Water	Letter (Optional)	Additional Information
X	No Data	X	No Data	D	Wire
0	No Protection	0	No Protection	F	Oil Resistant
1	Large Objects > 50 mm (2 inches). Effective against large surface areas of the body, such as the back of the hand. No protection against deliberate contact with a body part.	1	Vertical dripping water, tested for 10 minutes	H	High Voltage Apparatus
2	Medium Objects > 12.5 mm (.49 inches). Effective against surface areas of similar size as the fingers.	2	Tilted dripping water, tilted up to 15°, tested for 10 minutes	K	Testing conducted under high pressure (up to 1450 PSI or 100 Bar) and high temperature (up to 80°C or 176°F) conditions.
3	Small Objects > 2.5 mm (.098 inches). Effective against tools, thick wires, etc.	3	Falling spray water at any angle up to 60°	M	Device in Motion
4	Mini Objects > 1 mm (.039 inches). Effective against most wires, skinny screws, large ants, etc.	4	Slashing water against enclosure in any direction	S	Device is Standing Still
5	Micro Particles > 0.5 mm (.01968 inches). Dust is not entirely prevented but protects against quantity ingress sufficient enough to allow operation.	5	Nozzle-projected water against enclosure at a rate of 12.5 liters per minute for at least 3 minutes
6	Dust Tight for up to 8 hours in vacuum-applied environment	6	Jet water at a rate of 100 liters per minute for at least 3 minutes in any direction	W	Specific Weather Conditions
		7	Immersion up to 1 meter deep for 30 minutes
		8	Immersion up to 3 meters deep for a time agreed upon with manufacturer
		9	Power high-temperature water jets at a rate of 14 to 16 liters per minute at a temperature of 80°C/176°F for 2 minutes

How IP Ratings are Determined

To identify the level of protection provided by an electrical connector or other piece of equipment. For the protection against solid particles, the IP rating is based on several factors, including the size of the particles that the equipment can resist, the amount of dust that can enter the equipment, and the ability of the equipment to maintain its protective characteristics after exposure to dust.

For protection against water, the IP rating is based on several factors, including the type of water (e.g., rain, spray, jet, etc.), the duration of exposure to water, and the pressure of the water.

The specific test methods used to determine the IP rating of a piece of equipment are outlined in the International Electrotechnical Commission's (IEC) standard 60529, Degrees of Protection Provided by Enclosures (IP Code). This standard provides detailed guidelines for testing and rating the protection provided by enclosures against the ingress of solid particles and water.

Common IP-Rated Products

There are several common IP (Ingress Protection) ratings for electrical connectors. However, it's important to note that these ratings are only a guide: there can be variations in the level of protection offered by connectors with the same rating. It's always a good idea to carefully review the specific ratings and certifications of any connector you are considering using in your application. To minimize your risk of selecting a product that does not perform as well as the IP rating listed, only work with trusted manufacturers, such as iCONN Systems.

Some of the most common IP-rated connectors that we deliver include:

iMINI iSENSOR Series

All iMINI iSENSOR connectors in this series are rated IP67, meaning these connectors are dust tight and can withstand immersion in water up to a depth of one meter for up to 30 minutes.

iMATE Series

Our iMATE series also comes in an IP67 rating. However, this product line features numerous connector sizes that can be customized to meet even higher IP rating requirements, including the following:

IP68

These connectors are completely dust-tight and can be submerged in water to a depth of at least 1.5 meters (5 feet) for an extended period of time (typically at least 30 minutes) without any water ingress or damage.

IP69K

These connectors are built for the most extreme environments. They are completely dust-tight and can withstand high-pressure, high-temperature water jets from any direction without any water ingress or damage. The "K" in the rating signifies that the testing was conducted under high pressure (up to 1450 PSI or 100 bar) and high temperature (up to 80°C or 176°F) conditions.

What Else Should You Consider When Choosing Electrical Connectors?

While this IP ratings chart offers helpful guidelines, there are many other factors you should consider when choosing a connector assembly. Our buyer’s guide, How to Get the Best Connector For Your Project, will help you avoid costly mistakes by considering the most important factors, including logistics, regulations, your environment and more.

Our team can help you find standard connectors or design and manufacture custom solutions to withstand the harshest environments. If you’d like to learn more, schedule a time to connect with us.

Custom Circular Connectors: Key Considerations

efreemon@iconnsystems.com (Evan Freemon) — Tue, 30 Aug 2022 14:46:37 GMT

Few details will influence a product's success as significantly as its electrical design. Customers often need turnkey solutions that are both rugged and field-installable. While more affordable off-the-shelf connectors can meet a variety of application specifications, it's not uncommon for this combination of attributes to require customization, which may increase the upfront cost of ownership.

Custom circular connectors may cost more upfront but can significantly enhance lifespan, reliability and usability, making them more cost-effective. This article will help you understand your many options for power and data connectors and how specific design details can impact lead time, cost of ownership and ROI.

Understanding all factors associated with developing, scaling and manufacturing a customized part can help product teams optimize time and expenses.

Circular Connectors vs. Rectangular Connectors

All electrical connectors come in two basic shapes – circular or rectangular. Both bodies share a number of similar performance characteristics, but certain design details set them apart. Shape, in particular, plays a significant and often underappreciated role in a connector's performance and reliability.

Rectangular Connectors

Rectangular connectors have corners that create more surface area compared to circular connectors. This allows designers to fit more contacts into a smaller space. By nature, rectangular connectors are also modular, offering engineers more configuration flexibility. For example, you might arrange multiple single connectors side-by-side to conserve space or integrate power, coax, signal or fiber optics into a single rectangular connector.

Challenges with Rectangular Connectors

Any connector's signal or power strength depends on the stable and secure touching of two contact surfaces. Unfortunately, in some cases, users report issues with poor contact quality, resulting from either the low-quality design of the internal components or inadequate manufacturing practices that jeopardize the connector seal.

Additionally, while a boxy form can be beneficial in some regards, rectangular shapes can also create some inefficiencies. For example, a rectangular connector wastes a lot of space in low pin-count designs.

Circular Connectors

A circular connector product literally cuts corners, decreasing the diameter of the receptacle to meet spatial demands — particularly in low pin-count designs. Its cylindrical shape also provides exceptional terminal strength and a more streamlined fit, making circular connectors the preferred choice for applications involving a high potential for mechanical turbulence or impact damage.

Take food and beverage manufacturing, for example, where equipment must frequently endure high-pressure wash-downs and sterilization. Rectangular connectors (especially when configured side-by-side in close proximity) create crevices that are susceptible to debris and moisture. Without a proper seal, this can lead to oxidation, poor connectivity and cable failure.

With their sleek design and secure mechanical couplings, circular connectors can be configured to achieve exceptional IP ratings and offer better run-off, reducing the risk of corrosion, hygiene and reliability issues that can result.

Common Applications

Circular connectors are most common in free-hanging connections. While circular connectors are an obvious fit for round cabling and high-speed systems, their value can be observed in numerous applications across virtually any industry.

Challenges with circular connectors

Circular connectors are commonly viewed as more difficult and expensive to customize, especially when designing for miniaturized electronics. This is partly due to their smaller surface area, which limits the number of possible pin arrangements and makes it difficult to achieve higher levels of power or signal strength.

Additionally, circular connectors often require more ancillary pieces, which can increase the time and costs associated with parts and assembly. For example, affixing a circular connector and fortifying strength may require bulkheads, jam nuts, or flange mounts.

How Custom Circular Connectors Save Time and Costs

We use reverse engineering to create all-new high-performance product lines that help control the time and costs associated with customized circular connector projects.

Take our iMINI series, for example. The iMini product line features three unique circular connectors -- each designed to optimize pin density and placement. With cable dimensions as small as .27 inches, multiple contact configurations, up to 12 contacts and a 300V rating, this series provides product teams with an off-the-shelf, yet customizable solution that works in tight spaces and meets higher power and signal demands.

Likewise, we developed our iMate iCPC connector series to enhance the durability and performance of circular plastic connectors (CPCs) while simplifying field assembly labor.

Overmolding played an essential role in the success of this connector series, but not without its share of challenges. The overmolding process involves high degrees of heat and pressure — not ideal for certain connector parts. To overcome this challenge, we used gold-plated screw machined contacts that can withstand higher temperatures and pressures.

By improving the durability and IP rating of CPCs, we effectively reduced indirect cost factors associated with downstream maintenance. We also eliminated the pinch-point associated with mechanical strain relief (which often becomes a failure point in applications involving constant flex). Lastly, we chose to machine the mounting holes in the panel mount receptacle flange (rather than molding them), allowing us to fill customer requests as though they are standard offerings without the inventory or lead-time.

Download the full case study to learn more.

Design & Manufacturing Considerations

The growing demand for customizability has given rise to a new era of design that focuses on modularity. Modular design allows the customer to piece together a connector solution by choosing from a catalog of different parts. Rectangular connectors are often viewed as the superior choice for modular design and customization. However, circular connectors are just as versatile and adaptive with the right manufacturing partner.

Optimizing your circular connector requires a thorough understanding of the number of wires involved in the connection, the required gauge, the type of receptacle needed for the application and whether the connector needs to be field-attachable or field-installable and easily serviceable or not.

There are two main circular connector types:

1. Circular metal connectors (CMC) are all metal and feature a strong construct and secure mechanical connection.

2. Circular plastic connectors (CPC) are all plastic, making them lightweight and more resistant to extreme heat (with the right thermoplastic material).

Contact Pin Material

Contact pins are responsible for completing the electrical connection function. The quality of a connector's power or data transmission depends on the type of metal used to coat or construct contact pins. Metals have different levels of conductivity (i.e., the degree to which heat or electrical current is transmitted). Pure metals offer the highest degree of conductivity, while alloys offer lower levels.

The Conductivity of Metals - Highest to Lowest

Silver
Copper
Gold
Aluminum
Zinc
Nickel
Brass
Bronze
Iron
Platinum

Wire Gauge and Amperage

Wire gauge refers to a wire’s diameter, which determines its weight and the amount of electrical current it can safely carry (i.e., its electrical resistance). Amperage refers to the electric current’s strength.

Wire gauge and amperage are mission-critical details that can significantly impact performance and safety. If the gauge is too small for the electrical load, the wire can overheat. Without proper overmolding and insulation, overheating can melt through the cable jacketing and increase the risk of shock or electrical fires.

Download this guide to ensure you calculate the right ampacity.

Terminal Bond

You can affix a connector to a cable using two primary methods:

1. Crimping adjoins a wire to a wire or a wire to a terminal using a process that deforms or compresses metal parts until they form a gas-tight bond. This method is faster and simpler to perform and offers better water ingress protection. It's also more expensive due to tooling costs.

2. Soldering adjoins a wire to an electrical component by melting solder material onto the joint, thus creating a permanent bond. This method uses less tooling and is more economical but involves a high heat process (not ideal for certain inserts) and solder material that contains lead, which does not comply with RoHS requirements.

Coupling Mechanism

A mating or coupling mechanism refers to the mechanical design used to plug and unplug two circular connector ends. Generally speaking, there are three basic types of coupling mechanisms -- each with varying degrees of form and function.

Mounting

Circular connectors can be mounted in-line on a cable end or to panels or circuit boards.

Accessories

The ancillary parts and pieces of a circular connector can be divided into two categories:

Structural:
Installation or Mounting:

Positioning pins
Clamp rings
Coupling rings
Sealing rings
Guide pins
Positioning keys
Cable clamps
Gaskets

Coils
Bolts
Screws
Nuts

When To Choose A Circular Connector Design

When you understand the key considerations involved in designing a successful electrical assembly, choosing the right connector for your application becomes far less challenging. We recommend exploring a circular connector design if:

✅ Your product must pass an IP rating of 67 or higher.

✅ Your product must meet IEC and RoHS compliance requirements

✅ Your product has spatial limitations

✅ Your product will operate in harsh environments

✅ Your product will be exposed to corrosive environments

✅ Your product will endure above-average levels of vibration, shock, temperature or pressure.

✅ Your product requires quick and secure mating and unmating.

✅ Your product will operate in environments with high levels of EMI/RFI interference.

If you’re just starting a new project or need help defining your application specifications, the technical team at iCONN Systems is here to help. Our portfolio of circular connectors can meet even the most stringent industry requirements and application demands while controlling time and cost factors to deliver added value.

Learn more about our custom connector solutions.

Schedule a consultation today.

Biotechnology Trends Transforming Patient Care

efreemon@iconnsystems.com (Evan Freemon) — Thu, 18 Aug 2022 14:45:18 GMT

The global pandemic accelerated both the development and adoption of biotechnology — a field of research as impactful as it is controversial. Biotechnology trends are transforming modern medicine, enabling doctors to diagnose, treat and care for patients with greater speed, safety and effectiveness.

Here are the top trends with the greatest potential to reshape the patient experience and the future of healthcare.

6 Biotechnology Trends With The Greatest Impact

Rapid Drug Development

The rapid release of the COVID-19 vaccine underscores the importance of speed and safety in pharmaceutical development. By early 2021, experts estimate that COVID-19 vaccinations reduced the total number of new cases by 4.4 million. We have biotech data to thank for what is now considered the fastest vaccine ever created in history. Rather than amassing thousands of human test subjects for time- and cost-consuming trials, biotech data allowed researchers to create simulations that explored how the human body would react to new drugs. As a result, researchers expedited the testing and approval process, shortened drug production timelines and ultimately improved patient outcomes.

Personalized Medication

Traditionally, drug developers formulated medications for only the widest segment of society. Those with a unique immune response were forced to either endure side effects or search for a more effective treatment option. Today, scientists are using genomics to formulate medications that benefit individuals. Tailor-made medications combine patient data and insights from screened clinical trials to greatly improve efficacy and safety ratings. Individualized drug development can also drastically lower side effects and other implications of long-term dependence on prescription drugs.

Gene Therapy & Gene Editing

Gene therapy and gene editing are among the most controversial advances in biotechnology. In its infancy, scientists experimented with genomics as an approach to treating conditions specific to missing or dysfunctional genes. Today, doctors experiment with gene technology to address numerous diseases, including leukemia and lymphoma, both of which are among the most common types of cancer.

One approach involves swapping out an unhealthy or dysfunctional gene with a healthy, fully-functional copy. Scientists can also “deactivate” a dysfunctional gene to prevent the development of a genetic condition or treat existing conditions by introducing a new or modified gene into the body. With 50% of childhood deaths attributed to genetic disorders, the benefits of refining this branch of medicine are impactful. However, understanding how to manipulate genes without triggering an immune response continues to challenge scientists.

Synthetic Biology

Also leading the headlines in controversy is synthetic biology. Synthetic biology involves reengineering organisms to give them new abilities that make them more useful in medical applications (amongst others.) Though similar to gene editing, synthetic biology is slightly different. Scientists retrofit genes with larger stretches of DNA that have either been harvested from another organism or engineered in a laboratory.

Today, this biotechnology trend is primarily used as a research tool to help scientists better understand how genomes work. As research advances our understanding of genetics, scientists hope to unravel the mysteries of cellular signaling, design advanced diagnostics capable of pinpoint accuracy and develop new therapies for hyper-targeting diseases. In the UK, scientists are already using synthetic biology to create living systems that produce small molecules. In turn, scientists hope to develop medications through biological instead of chemical processes, effectively replacing chemistry in pharmaceuticals and resulting in medications that work with greater speed, safety and efficacy.

Advanced Treatment for Life-Threatening Conditions

With one in two men and one in three women at risk for developing some form of cancer in their lifetime, one of the most powerful use cases for personalized medicine is in the treatment of life-threatening conditions. Using genomics, scientists can gain a deeper understanding of a person’s genetic makeup to determine how their body will react to specific cancer cells and treatments. In aggressive cases where time is of the essence, the ability to eliminate trial and error and get a patient started on the best possible treatment for their body’s unique genetic makeup could significantly improve prognoses and outcomes.

Biotechnology Trends Have an Underlying Connection

Access to information is the common thread tying together numerous advances in medical science and the transformative impact biotechnology trends have on the patient experience. Using sensor technology and the Internet of Things (IoT), healthcare providers capture patient data at the point of care and communicate that information in real-time, generating unprecedented volumes of up-to-the-minute data biotech researchers can use to understand broad impact and validate theories.

As data infrastructure continues to improve through the integration of artificial intelligence and machine learning, scientists will gain the insight needed to identify trends and biomarkers across an expansive data landscape, leading to greater accuracy, faster diagnostics and treatment, and better overall patient care.

The complex medical devices, sensors and systems powering today’s biotech innovations require next-level cable and connector solutions. iCONN Systems specializes in working with product teams to customize some of the most advanced cable and connector assemblies available.

Learn more about our solutions for biotechnology.

5 Amazing Innovations In Unmanned Underwater Vehicles

efreemon@iconnsystems.com (Evan Freemon) — Fri, 27 May 2022 14:37:08 GMT

Between the sheer inaccessibility of the deep sea and its many dangers for a human operator, underwater environments represent the perfect testing ground for autonomous vehicle technology. One of the greatest challenges engineers have faced in this endeavor involves the volatile relationship between electrical components and water. Sophisticated machines require a sophisticated power supply that neither limits exploration nor puts technicians and equipment at risk. To fully understand this sentiment, it’s important to recognize the amazing innovations in unmanned underwater vehicles (UUV) and the industrial applications driving the need for more reliable electrical connectivity.

Examples of Unmanned Underwater Vehicles

Military Applications

Unmanned undersea vehicles have become an essential part of defense, with the US and China making significant investments in them. The use of artificial intelligence makes them ideal for military applications, such as surveillance missions and collecting data.

Unmanned maritime vehicles (UMVs) can also use sonar to detect and track other submarines that could pose a potential threat in real time.

Remotely Operated Research Vessels

Autonomous underwater vehicles (AUVs), or underwater gliders, can help scientists better understand deep-sea environments by mapping the depths of the ocean floor, measuring temperature, light and detecting the presence of life. They can even use unmanned systems to explore geological formations or shipwrecks.

AUVs for Oil and Gas

Before oil and gas companies can construct subsea infrastructure, they need to map the ocean floor. Remote-controlled autonomous underwater vehicles can take clear snapshots of the environment without putting anyone in danger.

5 Innovations in Unmanned Underwater Vehicles

1. Sophisticated Sensor Technology

Released in February 2021, HUGIN Endurance is an Automated Underwater Vehicle (AUV) equipped with decision-making capabilities. The vessel is built for long-range missions, including commercial and military surveying and maritime patrolling up to 1,100 km in a single trip. But the real marvel is its capacity to process and use data to handle edge cases that are as challenging as they are rare. With highly sophisticated surface and underwater sensor technology, the HUGIN Endurance is intelligent enough to make operational decisions around unexpected events or failures by using data to switch between redundant modes of operation.

2. Multi-Static Radar Systems

In addition to sophisticated sensor technology, unmanned underwater vehicles have adopted advanced sonar and radar systems for the detection and localization of underwater targets — particularly in situations with very low acoustical backscattering. Multiple monostatic radar technology offers several views from different angles, allowing technicians to survey and map underwater environments like the sea floor and view different aspects of a target at the same time with astounding resolution and quality. Due to the geometries involved in this kind of radar system, they require transmitter receiver pairs capable of high processing power compared to a single radar and an advanced level of data fusion to make sense of spatially-diverse signaling.

3. Automated Data Analysis

Beyond processing and transmitting data specific to a mission, the spatiotemporal complexity involved in currents, tides, topographic disturbances, pressure changes, and weather effects requires that unmanned underwater vehicles be capable of continuous and instantaneous change – a feat only possible with artificial intelligence. By integrating onboard sensors with other remote technologies, third-party sensors and AI, today’s most innovative unmanned underwater vehicles can interpret volumes of data, mimic human intuition and make decisions to refine maneuverability, respond to a failure or adapt to account for variable issues and elements.

4. Highly Articulated Maneuverability

Traditionally, underwater mobility has been hindered by cable-connected control stations, rendering them incapable of executing precise movement around marine life, shipwrecks, and other fragile obstacles. Today, engineers are taking pointers from sea creatures and exploring the use of biomimetic propulsion systems (propulsion that uses flapping fins rather than rotary propellers). Paired with refined software processing algorithms that collect and transmit huge amounts of data, underwater crafts are now capable of cable-free, highly articulated maneuverability, allowing humans to explore uncharted territory.

5. Battery Life & Power Charging Stations

Unmanned underwater vehicles -- particularly those equipped with the latest innovations -- are limited by the amount of power needed to operate. In many cases, a craft can only last about 24 hours before having to resurface, offload data and recharge. To improve mission durations, engineers have outfitted underwater vehicles like the HUGIN Endurance, with pressure-tolerant Li-Ion batteries that can power operations for up to 15 days without the support of a mothership.

Electrical Connectivity For Unmanned Underwater Vehicles

Though wireless charging technology exists, there is no substitute for the efficiency of cable-connected electric power charging, which presents its own set of challenges. Resurfacing is a calculated risk that requires time and energy. Taking electrical connections underwater is also a calculated risk. One of the most innovative advances in interconnect technology is the invention of niobium connectors, which allow technicians to mate and unmate electrical connectors while completely submerged in water.

When exposed to water, niobium contacts form their own passive film, which acts as an insulator that electrically isolates the contact from surrounding water. When mated, this film is removed, restoring the flow of power as soon as voltage is applied. iCONN System’s patented niobiCONN technology is the safest and most reliable way to form underwater electrical connections.

Learn more about our niobiCONN connectors.

Considering Injection Molding Services? Here’s What You Need To Know

efreemon@iconnsystems.com (Evan Freemon) — Mon, 21 Feb 2022 18:48:37 GMT

If you’re considering injection molding services, you’re already aware that this process allows design teams to achieve greater specificity at higher volumes. What you might not realize are the advantages of choosing to work with a service provider versus producing injection molded parts in-house. Here’s what you need to know.

The Benefits of Injection Molding

Injection molding streamlines the manufacturing process and allows the mass production of electronic parts. More importantly, it enables the manufacturer to reduce material waste, enhance product quality and durability and lower the time and cost required to fill orders.

Ultimately, these benefits create a greater threshold for innovation for product teams.

In our technology-driven world, a product team’s ability to innovate is their most important competitive advantage. Through innovation, product teams can leverage unique opportunities in growing markets. Consider the medical field, for example.

Historically, parts were large and clunky to produce, especially those involving electronic components. Because advances in injection molding capabilities now enable highly-detailed product design, product teams harness this technology to dramatically reduce the size of connectors and cable assemblies, driving significant advances in microscopic medical technology, such as implantable medical devices with sophisticated sensory capabilities.

Along the same lines, injection molding allows product teams to create more aesthetically-appealing solutions. In one case, iCONN Systems helped an LED lighting company design a power distribution system that could be installed and concealed in various cabinet sizes. The lighting system they developed involved numerous intricate parts that would have required months of manufacturing time and significant costs, were it not for advances in injection molding capabilities.

Partnering with a Provider for Injection Molding Services

Injection molding supports high volume production for less time and money. The ROI of bringing injection molding services in-house may seem to make sense at first. However, the upfront cost is significant and, without the proper expertise, design teams can encounter numerous quality issues, such as flow lines, sink marks, warping and more.

New product teams may not know how to get the most value out of their investment, such as building texture right into the mold to avoid the time and cost associated with a second process. In addition to initial costs, product teams should also consider the cost of tooling, which tends to be high, and the price for repairs and downtime should mechanical issues arise.

Getting The Most ROI

Partnering with a provider for injection molding services lowers overhead cost and ensures access to a dedicated team of engineers with specialized expertise in injection molding processes. Additionally, their vast experience working with other product teams in similar industries can help your organization enhance products, avoid common injection molding problems and take innovation to market faster than trying to adopt capabilities in-house. That said, not all injection molding service providers offer the same level of quality.

How to Find The Right Provider

As a pivotal part of the manufacturing process, we encourage product teams do due diligence when searching for an injection molding provider. Look for the following ‘trust signals’ when qualifying a potential provider:

Case studies illustrating the provider’s engineering expertise and success in specific applications.
Certifications proven to improve efficiency and effectiveness, such as ISO 9001 for Quality Management Systems (QMS).
Value-added services, such as rapid prototyping, CNC machining and cellular manufacturing.
Vertical integration, which ensures cost and time efficiency and, more importantly, service continuity.
US-based operations that uphold higher quality control standards and support the American economy.

Above all else, your provider should have a proven track record for lean, highly- coordinated production. If your organization is considering injection molding services, we can help. Contact us to learn more

Selective Soldering - The answers you seek

RmRegole@iconnsystems.com (Rick Regole) — Mon, 20 Dec 2021 15:00:00 GMT

Soldering is a technique used to affix two metal surfaces mechanically and electrically — for example, flex circuits (also referred to as printed circuit boards (PCBs) and electrical connectors. The process involves a metallic material called solder and a heat source (selective solder equipment) to melt the solder, thus creating a joint between the two metal parts.

In many applications, a gas torch or furnace is used to melt the solder solution, allowing it to flow into through-holes or spaces to create a bond. When applied correctly, these heat sources are perfectly safe and do not harm the surrounding components. However, soldering delicate electronics like printed circuit boards (PCBs) requires special consideration.

PCBs are flat, thin, intricate circuitries used in medical equipment, consumer electronics, communications equipment, and more. With the rapid evolution of digital technology, the PCB market has grown substantially over the last decade and is expected to become a $76 billion industry by 2026. As manufacturers continue to struggle with supply chain disruptions post-pandemic, the added pressure of increasing the benefits of selective soldering is expected to remain a pain point for many. However, thanks to advanced technologies like selective soldering, leading manufacturers like iCONN Systems can effectively meet the demands of the market and produce high-volume, high-quality products in-house.

Traditional PCB Soldering Methods,

In large-scale manufacturing, technicians might use selective wave soldering, which involves gluing components onto the PCB surface before running the entire piece through a molten solder wave. Wave soldering is efficient and effective; however, the systems are costly and difficult to operate, which can lead to quality issues, such as insufficient fills or voids within the solder joint.

In smaller manufacturing operations, skilled hand operators may use a soldering iron to individually bond each component together. Hand soldering involves great attention to detail, which can result in a high-quality product, but it also takes time, which is not always practical in high-demand, high-volume situations. This method also increases the risk of human error, making quality control a more tedious task.

Selective Soldering Technology

In today’s technologically advanced manufacturing landscape, the solution to most problems involves automation. Soldering flex circuit components is no exception. Enter — selective soldering.

Selective soldering uses sophisticated robotic machines, computer programming, and laser soldering to affix flex circuits to connectors with incredible precision, speed, and accuracy. Thanks to automated technology, the process requires minimal human involvement, resulting in a higher quality product. Furthermore, selective soldering machines are less expensive to operate, lowering the cost of production while simultaneously increasing productivity and consistency on the line. Most importantly, these machines allow manufacturers to keep up with market demand.

Eliminate the expense of wave solder pallets
Independently control each solder joint
Minimize thermal shock
Reduce operating costs
Improve product consistency

Selective soldering is just one of the many ways iCONN Systems adds value to products and services. Click here to learn more about our extensive capabilities.