Omnetics Connector Corporation, based in Minneapolis, Minnesota, designs and manufactures micro- and nano-miniature electronic connectors used across defense, aerospace, medical, and other advanced technology sectors.
With more than 30 years of experience and a catalog of over 10,000 products, the company develops both standard and custom interconnect solutions engineered to meet demanding environmental and performance requirements.
Engineering Custom Miniature Connectors
Micro- and nano-miniature connectors are widely used in soldier-worn communications, avionics, cochlear implants, and small satellite systems. While it is often straightforward to select a suitable commercial off-the-shelf (COTS) connector, certain mission-specific applications impose design constraints that can affect performance, reliability, and cost.
Omnetics provides design solutions that address these constraints, offering expertise in connector configuration, power requirements, and housing design. Miniature connectors are available in micro-D, circular, strip, and coaxial formats, and can be produced from a range of materials and finishes. When COTS solutions cannot meet the necessary form factor requirements for size, shape, or configuration, Omnetics engineers design custom miniature connectors tailored to the system’s operational environment.
Design and Packaging Support
Omnetics works closely with design engineers from early-stage development through final packaging. The company supplies both COTS and fully customized connectors and provides 3D STEP files for direct integration into CAD environments. This enables customers to assess mechanical fit and optimize system layouts.
At the system level, Omnetics assists in addressing cable routing and potential interference issues. In applications involving moving components, such as gimbals, the company helps prevent cable wear and abrasion through optimized routing and strain relief design.
Prototype Development and Evaluation
Once a concept is defined, Omnetics develops prototypes using in-house 3D printing and precision machining capabilities. Prototypes are tested for form, fit, and function to confirm compliance with all performance requirements. The company conducts a wide range of assessments to evaluate stiffness, strength, durability, and environmental compatibility under mechanical, thermal, and electromagnetic conditions.
These evaluations can also indicate where material or adhesive changes may be needed to ensure long-term survivability in operational environments.
Manufacturing and Process Optimization
Omnetics validates manufacturability through pilot production runs that assess design efficiency and yield while providing customers with production-representative samples for evaluation. These small-scale builds enable process optimization and ensure product consistency before full-scale manufacturing.
As the designer of its own contact systems, Omnetics develops automated crimping equipment that removes the need for manual stripping and hand tools, maintaining precision and repeatability across production runs.
Environmental and Qualification Testing
Custom miniature connectors must be qualified to meet industry standards defined by military, aerospace, medical, and other specialized sectors. Omnetics performs a wide range of in-house environmental and qualification tests to ensure reliability under demanding conditions. These include mechanical testing for vibration, tension, and fatigue; electrical testing for continuity, dielectric strength, and electromagnetic compatibility; and environmental testing for thermal cycling, humidity, corrosion, and pressure conditions.
Omnetics engineers assist customers in identifying suitable qualification tests and proven design alternatives. When independent verification is required, the company collaborates with third-party laboratories to complete external testing and certification.
Case Study: Military and Law Enforcement Helmet Systems
A manufacturer of military and law enforcement helmets required miniature connectors to support accessories such as cameras, lighting systems, and communication modules. Each accessory had distinct power and signal requirements while needing a lightweight, flexible, and waterproof connector.
Omnetics collaborated with the manufacturer to develop a series of breakaway connectors using toroidal springs and V-groove mating mechanisms instead of traditional latches or retention screws. Waterproofing was achieved through an O-ring and interfacial housing seal, with additional protection provided by a dual-mold structure. A soft inner mold promoted adhesion and sealing, while an outer layer supplied strength, strain relief, and form stability.
The resulting connectors met all size, flexibility, and environmental requirements and have since been adapted for use in additional applications.
Company Overview
Omnetics Connector Corporation is an AS9100-certified designer, developer, and manufacturer of miniature interconnection systems. The company’s products are produced to IPC 610, IPC 620, J-STD soldering, MIL-DTL-32139, and MIL-DTL-83513 standards. With a workforce of over 400 employees and a global presence spanning six continents, Omnetics continues to expand its portfolio of rugged, high-density, and mission-critical connector solutions.
Further information about Omnetics and its product range is available on the company’s website.
