How to Choose Connectors for Telecom Products custom?

Mar. 17, 2025

Design Considerations for Custom Connectors - Bead Electronics

Connectors are critical for applications in a wide range of industries. Devices are becoming smaller. Many manufacturers take a modular design approach to bring products to market faster.

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The increasing number of printed circuit boards requires more and more connectors. Standard connectors may not meet the requirements. Custom connectors let you design a connector that fits your exact specifications.

Learn more about custom connectors and what the design process involves.

When to Consider Custom Connectors

Custom connectors are beneficial in many circumstances. They can help you launch a new product more successfully. You can scale production more efficiently.

A new custom connector can help you meet product validation dates. You can avoid long lead times.

Common reasons a custom connector instead of a standard connector may be the best option include:

Mechanical and electrical/electronic requirements are not met with standard connectors
Needing extra protection from extreme environmental conditions
Failing to meet creepage and clearance standards
Failing to meet testing standards
Needing to align PC board contacts with your product's unique layout
Facing long lead times or the lack of specialized parts

Custom connector pins can help you change existing products or create new ones.

Modifications vs Completely Customized Connectors

You may be cautious about using custom connectors if you're in an industry like aerospace. The process for approvals and the need to meet stringent requirements can be a deterrent.

Custom connectors can use the design of Qualified Products List parts as a baseline. This provides assurance that the customized part will meet reliability and quality specifications.

Modifications to an existing design can reduce the cost of development. A modified product may have fewer prototyping and testing requirements. The approval may be easier than for a new design.

Consider the Application for Custom Connectors

The application is a primary consideration for custom connector design. The application helps determine all elements of a new custom connector.

Some applications require a more complex configuration than others. For example, a GPS unit probably needs a multi-pin connector. A simpler application may only need a wire-to-wire crimp connector.

How Often Will the Connector Be Mated and Unmated?

Connectors fall into one of several basic categories. The primary function of the connector helps determine which type you should choose.

Permanent

Permanent connectors stay mated for the life of a product. They won't undergo repeated plugging and unplugging.

Semi-Permanent

The design of semi-permanent connectors allows access for disconnection or replacement when necessary. You can access a semi-permanent connector when servicing or replacing a part.

Active

Active connectors need to withstand repeated plugging and unplugging. They need to be wear resistant.

Disposable

Disposable connectors have specific uses in applications like medical devices. Disposable connectors have a short or one-time use. Users dispose of them instead of attempting to sterilize them.

What Is the Service Environment?

The service environment of the connector helps determine some of its design considerations. Factors to consider include:

Operating temperature
Placement on the component
Exposure to substances like grease, chemicals, water, dirt, or dust

Vibration

For example, shielding can protect against unwanted electromagnetic interference radiation.

Connectors may need shielding because of their location on the component.

In applications with high mechanical stresses, the connector may need better rigidity. Bosses, threaded inserts, and pin serrations can help with retention.

Material Considerations

Many options for connector materials are available. The materials affect the weight, cost, and reliability of the component. Custom connectors give you the choice of materials.

You can select the base metal, contact plating, and the shell. Common base metals are:

Steel
Copper
Brass
Aluminum

Stainless steel is the best choice for a medical environment with frequent sterilization. Aluminum alloys are lightweight and can withstand harsh environments. Brass connectors can handle excessive wear.

Metals for contact plating include:

Tin
Gold
Nickel
Palladium nickel

Gold has excellent electrical and thermal properties. Nickel is a good choice for high-temperature applications. Palladium nickel is very durable with good electrical and thermal properties.

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Electrical Requirements

The voltage and current requirements for your application determine design details like:

Number of contacts
Contact size
Contact spacing
Wire size
Insulation material

For example, you'll need a stronger insulating material if high voltages are present. Wide pin spacing is another way to handle high voltages.

High-power signals like ground connections may require several pins connected together. You can also use dedicated pins for power, ground, and signal traces.

High-current applications can create heat from resistance in the pins. This can require extra cooling, which needs more space.

Space Requirements

Many connector applications have strict space requirements. Miniaturized connector solutions may be necessary. Space considerations include:

A large enough connector to handle the required current
Enough space for the necessary contacts or extra connectors
Space for adequate cooling and ventilation elements

Nesting or ganged arrangements are possible. Combined functionalities with fewer interfaces can help reduce the space a connector needs.

Termination Style

The connector termination attaches the connector to individual conductors. The conductors can be discrete wires or jacketed cables. PCB connector terminations include:

Through-hole
Surface mount
Pin-in-paste or through-hole-reflow
Press-fit

The termination style affects how well the connector is sealed. It also determines its mechanical strength.

Choosing a Custom Connector Manufacturer

Many factors contribute to the design of custom connectors. The service environment of the connector determines many aspects of custom connector design. The right design choices help ensure the connector performs reliably.

Bead Electronics provides custom, quick, and cost-effective pin manufacturing to provide for your custom connectors.

At Bead we're dedicated to meeting the specific needs of your project. We deliver quality products on time that meet and exceed our customers' requirements.

Choosing the Right RF Connectors for Your Communication Needs

At Intelliconnect, we understand that selecting the right RF connector is crucial for ensuring the reliability and efficiency of communication systems. RF connectors are designed to carry high-frequency signals, making them essential in industries such as telecommunications, aerospace, military, and medical applications. By choosing the right RF connector, you can minimise signal loss and maintain optimal performance.

Understanding RF Connector Types

Several types of RF connectors exist, each designed to meet specific requirements. BNC connectors, for example, are widely recognised for their quick connect and disconnect capability. They are commonly used in test equipment and low-frequency applications. For applications requiring higher frequencies and power levels, N-type connectors are the preferred choice. These connectors are robust and suitable for industrial and telecommunications use.

SMA connectors are valued for their compact size and high-frequency performance, making them ideal for precision applications, such as instrumentation and satellite communications. Meanwhile, TNC connectors have a threaded coupling mechanism and provide additional vibration resistance, making them reliable in rugged environments where stability is paramount.

Key Features to Consider

When choosing an RF connector, it is important to consider both its physical and functional characteristics. The shape and size of the connector should align with the system's requirements. Larger connectors, such as N-type, are often chosen for high-power applications, while smaller connectors, like SMA, are suitable for devices where space is limited. Another key feature is the connector's gender. Male connectors have a protruding centre pin, while female connectors have a receptacle. Ensuring the correct gender match is essential for compatibility.

Performance Specifications

Performance specifications play a critical role in the selection process. The frequency range supported by the connector must match the application's needs to preserve signal integrity. Impedance matching, typically 50 or 75 ohms, is equally important for minimising signal loss. Power handling capacity is another crucial factor, as connectors must be capable of withstanding the required power levels without degradation.

Environmental Considerations

Environmental factors also influence the choice of RF connectors. In marine environments, where exposure to saltwater and humidity is a concern, connectors made from corrosion-resistant materials such as stainless steel or nickel-plated brass are essential. Connectors with IP-rated seals can further prevent water ingress.

In medical settings, connectors often need to withstand repeated sterilisation processes. They may require biocompatibility to ensure patient safety. Aerospace applications demand connectors that endure extreme conditions, including high vibration levels and wide temperature variations. Such environments require designs that meet rigorous durability and performance standards.

Common Applications of RF Connectors

RF connectors are used in a range of industries. In telecommunications, they are critical for high-data-rate transmissions, where maintaining signal integrity is essential. Military and defence applications rely heavily on RF connectors, as equipment must perform reliably under harsh conditions. Medical devices like MRI machines and patient monitoring systems require precision and reliable connectors.

Identifying the Right RF Connector

Identifying the correct RF connector is an essential step in the selection process. Visual examination of the connector's shape, size, and coupling mechanism can help determine its type. Threaded connectors, such as TNC, are easy to distinguish from bayonet-style connectors, like BNC. Reference guides can also assist in identifying detailed specifications and compatibility with existing systems.

Material Selection

The materials used in RF connectors play a significant role in their performance and longevity. Corrosion resistance is particularly important in outdoor and marine applications, where exposure to moisture is a concern. Stainless steel and nickel-plated materials are often preferred for their durability in harsh conditions. In addition to resisting corrosion, high-quality materials help maintain electrical performance over time, ensuring long-term reliability.

Installation and Maintenance

Proper installation is critical to achieving optimal performance. Ensuring a secure connection prevents signal loss and reduces the risk of damage to the connector. Regular inspections can identify signs of wear, such as bent pins or loose fittings, which may affect performance. Maintenance practices, such as cleaning and re-tightening connections, can extend the connectors' lifespan and ensure continued reliability.

Cost Considerations

Cost is always an important factor when selecting RF connectors. While budget constraints are often a concern, balancing cost with performance requirements is essential. Cheaper connectors may not offer the same level of durability or performance, leading to higher long-term costs due to replacements or system failures. Investing in high-quality connectors can save money in the long run by reducing maintenance and downtime.

Custom vs. Standard Connectors

Depending on the application, you may need to decide between custom and standard connectors. Custom connectors are often designed to meet specific requirements, offering better performance and compatibility. However, standard connectors are more readily available and may be sufficient for less specialised applications. Assessing your needs and consulting an expert can help determine the best option.

Future Trends in RF Connectors

The field of RF technology continues to evolve, with trends focusing on miniaturisation and enhanced performance materials. Smaller, more compact connectors are being developed to meet the needs of modern devices, which are becoming increasingly lightweight and portable. Material advances also promise improved durability and performance, even in extreme environments. Staying informed about these trends can help ensure your systems remain competitive and up-to-date.

Conclusion

Choosing the right RF connectors for your communication needs is a crucial decision that impacts performance, reliability, and cost. At Intelliconnect, we are committed to providing high-quality RF connectors that meet the demands of diverse industries. You can make an informed choice by understanding the different types, performance specifications, and environmental factors. Whether you require off-the-shelf solutions or custom designs, we deliver products that meet your requirements. With a focus on quality, durability, and innovation, we ensure that your communication systems perform flawlessly in any environment.

For more Connectors for Telecom Products custominformation, please contact us. We will provide professional answers.

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