Aerospace Military and Defence Product of the Year
Company Name: Molex
Product Name: AirBorn SInergy Modular High-Speed Hybrid Connectors
Supporting Statement:
Executive Summary
Molex has expanded its AirBorn SInergy Modular High-Speed Hybrid Connector platform with the introduction of new high-power modules capable of delivering up to 25.0A within a standard connector bay. This enhancement extends the platform’s ability to combine power, high-speed data and RF connectivity within a single configurable connector architecture for aerospace, defense and space applications.
The development addresses a growing industry requirement for increased power delivery within space-constrained systems while maintaining reliability in demanding operating environments. By allowing power, signal and RF contacts to be integrated within one connector framework, the platform reduces the need for multiple connector systems, helping simplify design, qualification and supply chain management.
Supporting up to 25.0A power, 25Gbps data transmission and RF frequencies up to 40 GHz, the expanded AirBorn SInergy platform provides a single connectivity solution capable of addressing multiple system requirements. The result is improved design flexibility, more efficient use of available space and support for the increasing performance demands of next-generation aerospace and defense platforms.
Product Overview
The AirBorn SInergy Modular High-Speed Hybrid Connector is a ruggedized, modular interconnect platform designed for mission-critical aerospace, defense and space systems. The latest expansion introduces power contacts capable of delivering up to 25.0A within a standard module bay, representing a 12.5-fold increase in power capacity compared with previous platform options.
The platform combines three connectivity functions within a single architecture:
• High-power contacts supporting up to 25.0A
• High-speed signal contacts supporting data rates up to 25Gbps
• RF contacts supporting frequencies up to 40 GHz
A key differentiator is its position-by-position configurability. Unlike conventional hybrid connectors with predetermined layouts, AirBorn SInergy allows engineers to place power, signal and RF contacts according to application-specific requirements, enabling optimization of routing, density and system architecture.
The modular design supports up to five interchangeable connector bays that can be configured in a range of power, signal and RF combinations. Despite this flexibility, the platform maintains a compact footprint suitable for space-constrained applications.
Designed for harsh-environment operation, the platform is engineered to withstand temperature extremes, vibration, shock and moisture. Modules meet MIL-DTL-83513 specifications, while the new power contacts are designed to MIL-DTL-39029 contact crimp standards.
Innovation
The AirBorn SInergy platform demonstrates innovation through the integration of high-power, high-speed data, and RF connectivity within a single modular architecture.
Hybrid Power, Signal and RF Integration
The introduction of 25.0A power contacts within the existing modular framework enables power, signal, and RF connectivity to coexist within a single connector solution. This capability increases functional density while reducing the need for multiple connector systems.
Position-by-Position Configurability
The ability to configure individual contact locations provides a level of design flexibility not typically available in conventional hybrid connectors. This enables optimization for unique PCB layouts, mechanical constraints, and performance requirements.
Scalable Modular Architecture
The platform’s modular design allows up to five connector bays to be configured in different combinations of power, signal, and RF modules. This scalability enables a common connector platform to support multiple applications while reducing design variation and inventory complexity.
Thermal Performance
The new 25.0A power module is engineered to a 30°C temperature-rise baseline above ambient conditions and is supported by de-rating test data. This is especially relevant for aerospace and space applications where thermal management and reliability are critical.
Customer-Led Development
The platform expansion was guided by direct engagement with aerospace and defense customers, ensuring that development priorities aligned with evolving requirements for power delivery, modularity, signal integrity and system integration.
Industry Impact
The expanded AirBorn SInergy platform delivers benefits across design, integration, and deployment stages.
For design engineers, the platform provides a configurable solution for addressing increasing power, signal, and space constraints. The ability to consolidate multiple connectivity requirements into a single architecture reduces design complexity while enabling more efficient use of available board and enclosure space.
For systems integrators, the platform reduces dependence on multiple connector families and suppliers. This contributes to reduced bill of materials complexity, simplified procurement processes, lower qualification effort, and faster system integration.
For operators of aerospace, defense, and space systems, the platform supports higher power requirements without increasing connector count or footprint. Applications include avionics, radar systems, launch systems, satellites, combat vehicles, and other mission-critical platforms where reliability and space efficiency are critical.
Efficiency and Sustainability
The AirBorn SInergy platform improves resource efficiency by consolidating multiple connectivity functions into a single modular solution.
Reducing the number of connectors and interconnect points lowers material consumption, simplifies assembly processes, and reduces maintenance requirements over the product lifecycle. The platform’s high-power density also enables increased electrical capability without increasing connector size, helping to optimize both weight and space utilization.
The thermal design of the 25.0A power module supports efficient power delivery in constrained environments, contributing to system reliability and reduced thermal management challenges.
In addition, the use of a common connector platform across multiple applications can reduce design duplication, streamline qualification activities and support more efficient product development processes.
Conclusion
The expanded Molex AirBorn SInergy Modular High-Speed Hybrid Connector platform addresses a significant industry challenge: integrating higher levels of power, data and RF connectivity within increasingly compact and demanding aerospace and defense systems.
Through the introduction of 25.0A power modules, combined with high-speed data and RF capabilities, the platform provides a configurable and scalable connectivity solution that supports evolving system requirements. Its modular architecture, position-by-position configurability, ruggedized design and demonstrated thermal performance distinguish it from conventional connector approaches.
By reducing system complexity, supporting integration efficiency and enabling higher-performance mission-critical platforms, AirBorn SInergy demonstrates the technical innovation, practical impact and industry relevance that define a strong candidate for the IEA Product Awards 2026.
Entry ID: 7548
