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I/O Connectors

I/O connectors are critical in maintaining signal fidelity in high-speed communication interfaces. In applications such as 5G infrastructure, high-performance computing (HPC), and RF systems, signal degradation due to impedance mismatches, return loss, and crosstalk can significantly impact system performance. Our connectors are designed with controlled impedance pathways, differential signal routing, and optimized shielding architectures to ensure minimal insertion loss and superior return loss characteristics. Advanced materials, such as low-dielectric constant insulators and precision-milled contact geometries, mitigate signal distortion, ensuring optimale transmission even at frequencies exceeding 50 GHz. 

Material Options

High-grade plastic, stainless steel, aluminum, and copper alloys

Cable Diameter Range

1 mm to 20 mm

Temperature Range

-40°C to +85°C (can be customized depending on material)

Load Capacity

Up to 10 A (depending on connector type)

Vibration Resistance

Meets MIL-STD-810G standards
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Product Description

In power-intensive applications, thermal stability and efficient power distribution are crucial. Traditional connectors often suffer from localized heating, voltage drops, and increased contact resistance over repeated mating cycles. Our power I/O connectors incorporate low-resistance, high-conductivity alloy contacts with advanced plating technologies, such as hard gold or palladium-nickel over copper, to reduce oxidation and wear. Additionally, integrated thermal dissipation features, such as finned enclosures and vented housings, enable passive heat dispersion, ensuring stable operation under continuous high loads. These features are essential in EV battery management systems (BMS), industrial automation power modules, and aerospace power distribution networks. 

Corrosion Resistance

Salt spray tested for 96 hours

EMI Shielding

90 dB attenuation or higher

Mounting Options

Panel mount, through-hole, surface-mount

Compliance Standards

RoHS, UL, CE, IEC 61076-3-106

Custom Features

Waterproof, dustproof, locking mechanisms, color coding

UV Resistance

UV-stabilized polymer materials for outdoor use

Fire Resistance Rating

UL 94 V-0 or higher

Chemical Resistance

Resistant to oils, solvents, and cleaning agents

Thermal Expansion Tolerance

±0.1% per °C (customizable)

Dynamic Load Testing

Tested for over 50,000 insertion and withdrawal cycles

Precision Tolerances

±0.05 mm

Technical Advantages

Our I/O connectors, such as nickel-plated copper with ferrite absorbers, feature multi-layered shielding with hybrid conductive coatings to provide 360-degree EMI containment. Additionally, connector housings are designed with precision grounding tabs, conductive elastomer gaskets, and integrated ferrite cores to further suppress radiated and conducted emissions. These features ensure compliance with MIL-STD-461, CISPR 32, and IEC 61000-4-3 standards, making them ideal for defense communication systems, avionics, and medical imaging equipment. 

Our micro and nano-scale connectors are engineered with high-density contact arrays, fine-pitch termination, and ultra-low-profile housing configurations, allowing integration into miniaturized PCBs, flexible hybrid electronics, and wearables. Advanced manufacturing techniques, such as laser micro-machining and thin-film deposition for contact plating, enable precise alignment and durability in space-grade electronics, portable diagnostic devices, and next-generation consumer electronics. 

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Industry Applications

Aerospace & Avionics

High-speed data connectors with controlled impedance for ARINC 429, MIL-STD-1553, and Ethernet avionics networks. 

Automotive & EVs

High-voltage, high-current connectors with arc-resistant contacts for EV powertrains, onboard chargers, and HVDC distribution.

Industrial Automation

IP67/IP68-rated connectors with EMI shielding for EtherCAT, PROFINET, and high-cycle servo motor interfaces.

Telecommunications

Multi-gigabit RF and fiber-optic connectors with low insertion loss for 5G mmWave antennas and optical transceivers. 

Medical Devices

High-density micro-connectors with biocompatible plating for neural interfaces, endoscopic imaging, and patient monitoring systems. 

Defense & Military

MIL-DTL-38999 and 83513-rated connectors with redundant grounding for secure, low-latency battlefield communication networks. 

High-cycle durability and Contact Performance

Frequent mating and unmating cycles introduce mechanical wear, reducing connector lifespan and increasing electrical resistance. Our I/O connectors employ self-cleaning contact geometries, advanced lubricated plating finishes, and redundant spring-loaded contacts to achieve up to 10,000 mating cycles with minimal degradation. 

Material selection plays a crucial role in the longevity of I/O connectors. Our connectors utilize beryllium copper (BeCu) contacts for high spring force retention, liquid crystal polymer (LCP) insulators for thermal stability, and aluminum alloy shells with electroless nickel plating for lightweight durability. 

i/o connectors

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure precision in die-cast I/O connector housings for high-frequency applications?

Frigate uses high-pressure die casting with aluminum and zinc alloys to achieve tight dimensional tolerances critical for RF and high-speed signal connectors. Advanced CNC post-machining and surface treatments minimize micro-porosity and improve conductivity. This ensures the connectors pflegen low insertion loss, controlled impedance, and EMI shielding in GHz-range applications. 

How does Frigate’s die-casting process enhance the thermal performance of high-power I/O connectors?

Frigate employs high-conductivity aluminum alloys with optimized thermal mass distribution to improve heat dissipation in high-current connectors. Integrated finned structures and liquid-cooled interface designs can be die-cast directly into housings to manage thermal loads. Advanced plating techniques, such as silver or electroless nickel, further reduce contact resistance and improve thermal efficiency. 

How does Frigate’s manufacturing process improve the corrosion resistance of I/O connectors?

Frigate applies multi-layer surface coatings such as chromate conversion, anodization, or electroless nickel plating to protect against oxidation and galvanic corrosion. Die-cast zinc connectors benefit from self-healing zinc oxide layers. In contrast, aluminum connectors receive sealed anodic coatings for enhanced salt spray resistance, making them ideal for marine, aerospace, and outdoor telecom applications. 

What role does Frigate’s precision die casting play in miniaturized I/O connector designs?

Fregatte ist spezialisiert auf thin-wall die casting with tolerances up to ±0.05 mm, enabling compact, high-density connector designs. This is critical for applications requiring micro-pitch connectors with high pin counts, such as aerospace avionics, medical devices, and miniaturized industrial sensors. The use of high-strength zinc-aluminum alloys ensures durability despite reduced material thickness. 

How does Frigate optimize mechanical strength in connectors for high-vibration environments?

Frigate employs reinforced die-cast housings with structural ribbing to withstand high-G shock and continuous vibration in defense, railway, and industrial automation applications. Integrated locking mechanisms, floating pin interfaces, and dual-spring contacts further improve mechanical stability. Material selection, such as zinc-aluminum hybrid castings, enhances impact resistance without adding excess weight. 

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I/O Connectors

Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

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I/O Connectors

Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

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