Flex and Rigid-Flex Circuit Assemblies

Glenair QwikConnect Magazine • July 2022 • Volume 26 • Number 3

GLENAIR • JULY 2022 • VOLUME 26 • NUMBER 3

IPC 6012/6013 Class I, II, III, Types 1–4 Certified Production

COMPLETE CAPABILITIES: from connectorized flex circuits to rigid- flex circuit assemblies, PCBAs, and optical flex

NEW DIRECTIONS IN Flex & Rigid-Flex Assemblies

NEW DIRECTIONS IN Integrated Flex, Rigid-Flex, and PCBAs

Single-sided flex circuits Single-sided flexible circuits are the most common type manufactured by Glenair. They consist of a single conductor layer on a flexible dielectric film terminated with a thru-hole, ZIF or surface mount PCB connector. Single- sided flex circuits may be supplied as complex multi-branch assemblies. Or more commonly as simple point-to-point flex jumpers, such as from a board-level connector to an I/O interface connector. Glenair offers numerous point-to- point flex jumpers as standard catalog products with accelerated lead times. Glenair is one of the few manufacturers of turnkey, connectorized flex assembles

Various formats of flex circuits (metallic layer(s) of traces, usually copper, bonded to a dielectric layer, like polyimide)—are used to interconnect embedded electronic packages, displays, backplanes and other PCB components. Flex and rigid-flex circuits are considered superior to conventional wiring as they can be easily routed in three dimensions, are lighter and smaller than discrete wires, and offer virtually unlimited flex cycles in articulated applications. Flex and rigid-flex circuits are commonly deployed within avionic LRU’s and other complex electronic systems, as well as between articulating components, such as disk drive, robotic arms, and other electro-mechanical devices. Compared with traditional wiring, compact flexible printed circuit assemblies reduce system complexity and assembly time as well as enhance reliability. Due to their low mass and high circuit density, flex circuit assemblies are less susceptible to impact and vibration damage than conventional wire harness assemblies, making them an ideal choice in satellite applications such as articulated solar arrays, sensors, and antenna. As mentioned, the high electrical-connection density provided by flex and rigid-flex circuits delivers considerable weight and package size savings compared to wire and wire harnesses. This makes the medium an ideal choice for the reduction of all-up weights in aircraft and space systems. For this reason, flexible printed circuits

that will soon be making long length assemblies 96 inches and up. Glenair will offer

these extra-long flex circuits in one

are increasingly specified in place of conventional interconnect wire harnesses in weight-sensitive aero and space applications.

Flex and rigid-flex circuits are ideally suited for 3-D routing requirements in small form-factor electronics

QwikConnect • July 2022

continuous piece. Long assemblies of this type may be employed as replacements for complex multibranch EWIS wiring in commercial and military aircraft. Double-sided flex circuits Double-sided flex is also supplied to expand available circuit real-estate within the same basic envelope as a single-sided assembly. Connector terminations for double sided flex include straddle-mount designs for interconnection to conductive pads on both sides of the flexible dielectric film. Multilayer flex circuits Multilayer flex is supplied for applications that need three or more layers of conductors for termination to higher pin-count circular and multi-row rectangular connectors. These assemblies support their higher circuit density with bonded conductive layers that are interconnected with selectively plated through- holes called “vias.” Glenair can support up to 8 such layers in a conventional multilayer flex circuit build. Rigid-Flex circuits Rigid-Flex Circuits are hybrid constructions that consist of flexible circuit assemblies, laminated together with rigid board elements. Rigid-Flex circuits are used for surface mounting of electronic components or to provide strengthening or mounting features to the flex assembly. Glenair manufactures numerous variations of rigid-flex, including multi-layer assemblies with up to 27 layers. Rigid-Flex assemblies are also uniquely employed on flex-to-install designs that combine embedded PCB boards and flex circuitry. Supported connector terminations include thru hole, straddle, surface mount, and ZIF. Substrate options include DuPont ™ Kapton ® and Panasonic Felios.

Optical Flex Circuits Glenair optical flex

circuit assemblies are lighter weight, higher density replacements for conventional fiber wire assemblies. Typically

integrated with high-density MT ferrule terminations, the assemblies are designed for use with optical backplanes and card- to-card applications. Glenair optical flex circuit support singlemode, multimode, and specialty fiber as well as hybrid optical and electrical configurations that integrate the two technologies in multilayer assemblies. The principal design benefit of optical flex circuitry is the ability to implement fiber crossing or shuffle circuitry for the complex routing of fiber lines inside control computers and other types of LRUs. Glenair optical fiber circuit assemblies offer reduced installation time and termination errors, reliable, repeatable performance, superior optical fiber management, controlled low-skew routing lengths, controlled bend radii minimizing bend loss, and long length leads 12 inches and up, eliminating the need for splicing within an equipment enclosure. Glenair long-length leads are far more durable that conventional fiber ribbon cable when used in support of MT ferrules and connectors. For all assemblies, Glenair builds in accordance with the IPC-6012/6013 specification standard, although Military customers may alternatively cite specifications IAW MIL-PRF-31032. In both cases, we recommend leveraging our design team for optimization of connector pin-outs to reduce frequency of cross-overs that lead to higher layer counts and increased cost. Our application design and prototyping services are free and highly available.

QwikConnect • July 2022

Commercial Aerospace

MISSION-CRITICAL FLEX & RIGID-FLEX CIRCUITS Markets Served

Aerospace-grade rigid-flex circuit assembly

Glenair flex circuit interconnect assemblies for commercial aerospace applications are fabricated in accordance with the highest IPC assembly standards, and equipped with connectors, contacts, and termination designs suitable for use in avionics and other commercial aerospace LRU equipment. Assemblies are optimized for reliable life-of- system performance in pressurized aircraft applications characterized by such stress factors as vibration, shock, temperature extremes, and rough handling. PCB assembly materials are RoHS and REACH compliant.

TURNKEY CONNECTORIZED FLEX CIRCUIT ASSEMBLIES

Optimized for Harsh Aerospace Applications

Crimp-contact Series 79 for standard signal, power, high-speed and RF

Series 23 “better than QPL” SuperNine environmental and hermetic circular

Micro miniature Mighty Mouse and Series 806 Mil-Aero for size and weight reduction

Vita 66.1 and 66.4 optical backplane connector optimized for optical flex

QwikConnect • July 2022

ADVANTAGES OF FLEX CIRCUITRY FOR AEROSPACE APPLICATIONS:

High-Density Size and Weight Savings Save size, weight, and improve density compared to wire bundles Flexible, repeatable routing for complex 3-dimensional installations Broadest range of high-performance I/O and board connectors Optimized reliability: high-speed, high temp, high shock and vibe

Example of a simple rigid-flex application with mounting point stiffeners added

COMING SOON Fairway-Flex: up to 96 inch + continuous length multilayer flex circuits

Series 23 SuperNine and Micro-D flex assembly with discrete RF Coax lines for use in a Zone 2 avionics application

Flex assembly with Series 79 I/O connector and wide flex circuit traces for medium current transmission

Unique Ethernet and USB flight deck multibranch flex assembly with panel sealing

QwikConnect • July 2022

Military Defense

MISSION-CRITICAL FLEX & RIGID-FLEX CIRCUITS Markets Served

IPC 6012/6013 Class I, II, III, Types 1–4 Certified Production

In-process rigid-flex circuit, ready for PCB connector termination

Glenair’s flex circuit assembly cell is IPC 6012 / 6013 Class I, II, III, types 1–4, ISO 9001, and AS9100 certified. Glenair flex and rigid-flex assemblies utilize high-performance polyimide PCB materials. Standard FR-4 board assemblies are also available. All connectors used in the flex and rigid- flex assemblies meet or exceed military requirements for shock, vibration, corrosion resistance, environmental sealing, and shielding performance. All assemblies are optimized for size and weight reduction, as well as superior performance in high-speed, RF, and high-bandwidth optical applications.

LIGHTWEIGHT, SMALL FORM-FACTOR ASSEMBLIES

Optimized for Military / Defense Applications

Micro-D subminiature I/O connector to AlphaLink board connector assembly

Nanominiature Series 88 SuperFly flex jumper

Series 79 Micro-Crimp flex assembly with hybrid signal and power contacts

High-speed 10GbE flex assembly with El Ochito® datalink contact

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OPTIMIZED SPACE-SAVING

Packaging and Integration

Flex and rigid-flex circuit assemblies are ideal for space- constrained electronic packages and enclosures, or for interconnect systems that are required to flex in 3 axes during normal use. Flex and rigid-flex circuitry offers complete freedom to design boards and wiring for even the most densely-packed electronic enclosures. In mission-critical applications, the ability to reduce or even eliminate discrete wiring and FR-4 boards in favor of flex circuitry helps military defense application designers make the most efficient use of available space.

Stacked Micro-D I/O connectors with flex and rigid-flex circuitry

Hybrid rigid-flex assembly with RF coaxial cable and hermetic I/O connector

Complex multibranch military-grade Micro miniature flex assembly

Jumper assembly with Glenair SuperNine I/O panel connector and HD Stacker board-to-board interconnect

Unique-design PCBA with flex-to-install element

Glenair MT optical flex circuit assembly with shuffle circuit fiber line routing. Optimized for use with ruggedized Series 79 MT connectors.

QwikConnect • July 2022

Downhole Oil & Gas

MISSION-CRITICAL FLEX & RIGID-FLEX CIRCUITS Markets Served

Point-to-point rigid-flex assembly for a downhole tool application

Temperature-tolerant micro miniature flex circuit assemblies manufactured by Glenair are ideally suited for use in modular electronic transmission and sensor tools used as aids in directional drilling and geologic formation evaluation. Flex and rigid-flex circuit board assemblies terminated with Glenair Micro-D, Nanominiature, and special high- temperature Well-Master Micro-D PCB connectors are applied in applications as diverse as Measurement While Drilling (MWD), Logging While Drilling (LWD), slick line production tools, and other harsh downhole applications.

Glenair Nanominiature PCB connector: ultra high-density .025" contact-to-contact spacing solution

Glenair Micro-D subminiature PCB connector: micro high-density .050" contact-to-contact spacing solution

Glenair Well-Master 260° Micro-D PCB header with unique angled mounting ears and high temperature tolerance

QwikConnect • July 2022

ADVANTAGES OF FLEX CIRCUITRY FOR DOWNHOLE APPLICATIONS:

Optimal Harsh Environment Performance Withstands high levels of drilling shock and vibration Broad temperature tolerance Available non-magnetic materials Available 260°C low-profile PCB connectors Optimized reliability: high-speed, high-temp, high shock Ideally suited for double-sided component mounting Integration of active componentry

PROVEN PERFORMANCE DOWNHOLE

Connectorized PCB Flex Assembly Designs

Major Tool Types: MWD (Measurement While Drilling) LWD (Logging While Drilling) Wireline Logging Slickline Tools – Production Distributed Temperature Sensing (DTS) Pressure Temperature Sensing (PTS) Gamma Sensor

High-speed Glenair cylindrical PCB connector used in a tool segment interconnection flex jumper assembly

Rigid-flex point-to-point jumper with Series 79 Micro-Crimp connectors and a small form-factor hybrid fiber optic tool segment connector

Micro-D subminiature hybrid flex jumper with signal and power circuits

QwikConnect • July 2022

Space Vehicles

MISSION-CRITICAL FLEX & RIGID-FLEX CIRCUITS Markets Served

Space-grade rigid-flex circuit assembly

Ultra lightweight flex circuit assemblies manufactured by Glenair have traveled to and from orbit dozens of times on NASA and ESA platforms as well as on numerous commercial space-launch vehicles and satellites. Glenair connectorized flex circuit assemblies are available in configurations optimized for space with inherently radiation-resistant materials, NASA EEE- INST-002 screening, and lot traceability.

Space-grade FPC assembly for a GEO satellite application

SCREENED NASA ESA, JAXA

Glenair MT optical flex circuit assembly with shuffle circuit fiber line routing. Radiation-resistant fiber and NASA ASTM E595 outgassing

Inherently radiation-resistant materials, space agency screening, Class G space-grade interconnects, and lot traceability

QwikConnect • July 2022

ADVANTAGES OF FLEX CIRCUITRY FOR SPACE APPLICATIONS:

Optimal Size and Weight Reduction

Withstands high levels of launch shock and vibration Broad temperature tolerance Inherently radiation-resistant materials including optical flex NASA screening and lot traceability TRL 9 with space agency and commercial flight legacy

TECHNICAL READINESS LEVEL TRL 9

Connectorized PCB Flex Assembly Designs

"Clock spring" assembly with HiPer-D I/O connector for a satellite solar array actuator

Space-grade Series 28 HiPer-D to Series 80 Mighty Mouse I/O jumper

EMI/RFI filtered power transmission flex circuit assembly

Space-grade connectorized jumper assemblies

Rigid board assemblies with surface-mount components

Multilayer flex and rigid-flex assemblies

Hybrid rigid/flex assemblies

Rigid-flex Micro-D assembly with potted strain relief

QwikConnect • July 2022

FLEX AND RIGID-FLEX Specification Standards

GLENAIR FLEX AND RIGID-FLEX

The following tables describe, in brief, Glenair flex and rigid-flex manufacturing formats and specifications. Glenair recommends commercial customers specify IPC-6012/6013 standards of workmanship which are fully supported by Glenair. Military customers may alternatively cite specifications IAW MIL-PRF-31032. Manufacturing Formats and Specifications

IPC 6012/6013 Class I, II, III, Types 1–4 Certified Production

FLEX ASSEMBLIES

Design Formats

PADS • PADS PRO • Pro E / Creo • SolidWorks • Autodesk Inventor • CAM 350 • Altium • Valor • POLAR • XPedition

Manufacturing Formats

DXF • Gerber • ODB++ • IPC 2581

Layer Count

Max typ. up to 8

Termination

Thru hole • Reverse bare • Floating fingers • ZIF • Surface-mount

Conductor Width/Space

Lines: .003" • Spacing: .003" (dependent on copper weight)

Bend Radius (military)

Single Metal Layer: 4–6X overall flex thickness• Double Metal Layers: 6–10X overall flex thickness • Multi Layer Metal: 12–15X overall flex thickness Substrate: DuPont™ Kapton® polyimide flex adhesive and adhesiveless -60°C to 125°C Cover layer: DuPont™ Kapton® Stiffener: FR4 or DuPont™ Kapton® (metal stiffeners available upon request) Conductor: Copper, Constantan High-temperature materials and more available

Materials / Tg

Surface Finish

ENIG • HASL • Immersion Tin and Silver • Soft and Hard Gold

Specs and Quality Management

IPC-6013 Class I, II, III, types 1-3 • ISO 9001, AS 9100J-STD-001 Space

RIGID-FLEX ASSEMBLIES

Design Formats

PADS • PADS PRO • Pro E / Creo • SolidWorks • Autodesk Inventor • CAM 350 • Altium • Valor • POLAR • XPedition

Manufacturing Formats

DXF • Gerber • ODB++ • IPC 2581

Max Panel Thickness

Range of thicknesses from .010" to as thick as .250"

Layer Count

27 +

Via Technology

Blind, buried • Thru hole • Filled (conductive and non-conductive)

Conductor Width/Space

Lines: .003” • Spacing: .003” (dependent on copper weight)

Materials / Tg

Substrate: Nelco 4000, Rogers, Megtron, Polyimide, and more

Surface Finish

ENIG • HASL • Immersion Tin and Silver • Soft and Hard Gold

Specs and Quality Management

IPC-6013 Class I, II, III, type 4 • ISO 9001, AS 9100, J-STD-001 Space

DuPont™ and Kapton® are trademarks or registered trademarks of E.I. du Pont de Nemours and Company.

QwikConnect • July 2022

GLENAIR

FLEX, RIGID-FLEX, AND RIGID PCB Design Options

STANDARD DESIGN OPTIONS

Integrated Flex / Rigid-flex assemblies

Properly designed flex and rigid-flex assemblies offer significant space and weight savings compared to wire harnesses. Many design options are available, including integrated stiffeners, shielding, factory forming, selective bonding, termination, layer count and so on.

A Right-angle surface mount Nanominiature plug connector B Hatch shield and solid copper shield flex C Series 801 Mighty Mouse receptacle with PC tails

I Micro-D 37-pin connector J Silver paste shield flex

K Resistor, inductor, and capacitor L Series 88 SuperFly™ rear panel mount PCB receptacle M Black EMI film (suitable for commercial applications)

D AlphaLink® SL spring-loaded contact connector E Cross-hatch shield flex F Board-mount transceiver G Series 79 Micro-Crimp® right-angle PCB panel- mount receptacle H Solid copper shield flex

N D38999 Series II type hermetic PC tail receptacle connector O ZIF (Zero Insertion Force) termination P 6-layer rigid-flex circuit board with BGA Q Overmolded termination

SMALL FORM-FACTOR PCBAs AND FLEX-TO-INSTALL ASSEMBLIES

Integrated Design Examples

Complex double- sided PCBA and interconnect assembly with programmable electronics for a high- speed data aggregation application

Ruggedized FMC connectivity PCBA designed for modular incorporation into Ethernet, Fibrechannel, and/or DVI, SMPTE video system applications

Special accordion-fold rigid-flex PCBA with integrated flex cable and opto-electronic fiber-to- electrical media converter for a Gigabit Ethernet application

QwikConnect • July 2022

FAST-TURNAROUND MODELING AND PROTOTYPING SolidWorks • 3D Print Prototypes

MODELING AND 3D PRINT

Optimized for Rapid Prototyping

3D representation of flex assemblies using SolidWorks 3D printed “paper doll” outline mockups for fit checks with copper clad DuPont ™ Kapton ® to simulate actual flexibility Incorporation of customer-supplied wiring diagram and chassis information in laser-cut mechanical samples

Example SolidWorks and 3D printed paper doll prototype mockups produced by Glenair’s Integrated Flex Assembly team—typical turnaround 2–3 days upon receipt of request for most application designs

Complimentary quick-turn mockups produced by by Glenair: 28-layer rigid-flex, and 12-layer multibranch rigid-flex

HD Stacker board-to-board connector/flex mockup

3D MODELING OF BOX BUILDS FOR OPTIMAL INTEGRATION OF I/O INTERCONNECTS AND FLEX CIRCUIT ASSEMBLIES

Customer-supplied STEP file of box with panel cutouts Glenair value-added 3D model with connector size and flange modifications

In this example, customer supplied a STEP file of a box enclosure with existing panel cutouts. The Glenair engineering team used SolidWorks to design a specially-modified connector flange, enabling the use of a smaller, higher-density connector, for significant size-and weight-savings.

Electronic box builds are supported by software-based design and prototyping of I/O connectors and integrated flex circuits Process leads to optimized location and routing of internal assembly and I/O interface

This integrated system enclosure, complete with printed circuitry, I/O connectors, and power modules was designed and modeled in SolidWorks prior to production manufacturing.

DuPont™ and Kapton® are trademarks or registered trademarks of E.I. du Pont de Nemours and Company.

QwikConnect • July 2022

GLENAIR

FAST-TURNAROUND MODELING AND PROTOTYPING Design and Production Process

GLENAIR INTEGRATED PCB/FLEX ENGINEERING

From Concept to Design

The mechanical schematic design process typically takes one of two forms: either the customer presents a fully-realized mechanical design, or as is often the case, the process begins with a “napkin sketch” of the project. Here is an example of just such a rough design that kicked off a rigid-flex circuit assembly development process.

Glenair engineers utilized our Altium software to create a functional and problem-free mechanical design for customer review and modification prior to starting the build.

WIRING DIAGRAM

1 5 8 4 P2

RED 24 AWG WHT 26 AWG GRN 26 AWG BLK 24 AWG BLU 26 AWG YEL 26 AWG DRAIN WIRES VIO 26 AWG ORN 26 AWG

1 5 8 4 9

7 3

6 7 3 2

9 10 6

Electricals : The next step is to define the electricals. To approximate layer count, we need a wiring diagram “schematic” complete with signal types, currents, and shielding requirements. This is also used to determine ROM pricing. In this project, work to this point was completed in just 3 weeks. With the final design approved, we were ready for production manufacturing.

Validation test requirements : Glenair offers complete generation of PCB/flex fabrication data packages including component-level documentation. Most flex customers specify validation testing as a required part of the documentation package. Tests may include DWV/IR, continuity, impedance (eye pattern), and others.

QwikConnect • July 2022

SUFFERIN' SUCCOTASH! You got 'em all wrong!

POINDEXTER AND MR. PEABO

POPEYE

PINK PANTHER

CHARLIE BROWN

FRED FLINTSTONE

ARNOLD

SQUIDWARD

WILMA FLINTSTONE

YOGI BEAR

MR. KRABS

BULLWINKLE

BART SIMP

GOOFY

MIGHTY MOUSE

ODIE

REN AND STIMPY

BOBBY

QwikConnect • July 2022

GLENAIR

ODY

DEXTER

BUGS BUNNY

MARVIN THE MARTIAN

TASMANIAN DEVIL

SNOOPY

BETTY BOOP

CASPER

ROAD RUNNER

OLIVE OYL

PSON

FELIX THE CAT

PINKY AND THE BRAIN

MARGE SIMPSON

STEWIE GRIFFIN

ANSWERS: WWW.GLENAIR.COM/QWIKCONNECT DAFFY DUCK MOJO JOJO

SPONGEBOB SQUAREPANTS

QwikConnect • July 2022

FLEX, RIGID-FLEX, AND RIGID PCB ASSEMBLIES Application / Design Options

GROUND PLANES AND SHIELDS

Managing EMI emissions and signal line impedance are critical aspects of flex circuit design. Effective use of ground / shield planes, appropriate connector interfaces, and matched-impedance flex circuits delivers optimal high-speed signal integrity.

Full copper shield

Cross-hatch mesh shield

Hybrid solid/mesh

Silver epoxy

Polyimide-bared for contact grounding

Connector-to-flex shielding (soldered pin insert)

Stitched vias

Black Tatsua

STRAIN RELIEF OPTIONS FOR FLEX AND RIGID-FLEX

Reinforcing “wings”

Stiffeners at critical assembly points

Reinforced solder joint with potting

Molded epoxy encapsulant

RIGID-FLEX MOUNTING POINTS FOR IMPROVED VIBRATION AND SHOCK RESISTANCE

Typical examples of rigid-flex mounting points in connectorized flex circuit assemblies

QwikConnect • July 2022

GLENAIR

FLEX, RIGID-FLEX, AND RIGID PCB ASSEMBLIES Application / Design Options

FLEX, RIGID-FLEX, AND PCBA CONNECTOR TERMINATION OPTIONS

Pogo pin / spring-loaded contacts

Straddle mount

Thru-hole

Surface mount

ZIF (zero insertion force

Compliant pins

Direct termination

Solder termination with epoxy potting

FLEX AND RIGID-FLEX I/O CONNECTOR OPTIONS

Military aerospace grade circular: SuperNine D38999

Micro miniature aerospace- grade circular: Mighty Mouse

EMI shrouded precision- machined M24308

Environmentally sealed rectangular I/O interface

Ruggedized MT fiber optic I/O circular

Dual-gang modular I/O: Series 20 Super-Twin

Series 970 PowerTrip power connector I/O

Micro miniature push-pull QDC I/O

MULTILAYER AND DOUBLE-SIDED FLEX AND RIGID-FLEX DESIGN OPTIONS

Multilayer rigid-flex circuit assemblies—up to 27 layers—offer increased circuit density while still maintaining the medium’s dynamic 3D flex characteristics

Double-sided flex circuits increase circuit density and power handling

QwikConnect • July 2022

TURNKEY FLEX, RIGID FLEX, AND PCB ASSEMBLIES Production Lab

GLENDALE, CALIFORNIA IPC 6012/6013 Class I, II, III, types 1–4 ISO 9001, AS9100 Certified

Glenair Integrated PCB/Flex assembly production facilities are operated in accordance with commercial and military standards. Staff includes 200+ PCB and cable assemblers with J-STD-001 Space certification for special processes and ESD management.

• High-availability catalog components as well as custom design and manufacture • No minimums • We never obsolete parts

Automated Optical Inspection and Flying Probe Electrical Test

QwikConnect • July 2022

GLENAIR

Glenair’s PCB/Flex interconnect team is housed together under one roof. From electrical design to computer-aided manufacturing and assembly, the team has a well-deserved reputation for on-time delivery of even the most complex PCB/Flex assemblies.

QwikConnect • July 2022

BACKPLANE AND CARD-TO-CARD Optical Flex Circuit Assemblies TURNKEY, HIGH-DENSITY, MULTIMODE AND SINGLEMODE

SHUFFLE CIRCUITS AND OPTICAL FIBER CROSSOVER DESIGNS

High data rate Optical assemblies

FEATURES Connectorized optical harness assemblies and breakouts, SM and MM Shuffle circuits with low- loss multimode fiber Ribbonized MT leads up to 12 inches and longer BENEFITS Reduced installation / Superior fiber management Complex fiber routing in minimal space Controlled routing lengths (low-skew) Controlled bend radius for minimized bend loss termination time and improved reliability

FLEX

Adhesive layer on substrates to fix fibers in place

250μm colored optical fibers routed and bonded to substrates

Proper bend radius design at crossovers ensures long life and no impact on optical performance

Thermally-stable flame-resistant flexible polymer substrate

Cross-section of a two-layer optical flex circuit with crossover fibers

3D layout and routing designs in Fusion 360

Build-to-print per customer specifications

Single- and multimode fiber bonding

Optical fiber bonded to a flame-resistant Kapton substrate—rad-hardened and outgassed assemblies available High-density fiber-to-fiber spacing: 250 μm Optimized fiber layouts, bend radius, and routing for high fiber-count applications Industry-standard connector terminations including FC, SC, LC, and others plus Glenair Signature F/O terminations including MT, GC, GHD, GFR, Eye-Beam, and others

Optical Fiber Nominal OD 250um Fiber Types

Singlemode/Multimode

Operating Temperature

-40° to +100°C

Typical Minimum Bend Radii 0.5 inch Circuit Thickness .018 inch Flat and 3D Designs Yes Flame Resistance

UL-V1 or Better

Shuffle Circuits

Yes

Substrate

Kapton

QwikConnect • July 2022

GLENAIR

BACKPLANE AND CARD-TO-CARD Optical Flex Circuit Assemblies TURNKEY, HIGH-DENSITY, MULTIMODE AND SINGLEMODE

OPTICAL FLEX ECOSYSTEM

Integrated SM and MM Optical Flex assemblies

Ecosystem includes high-data-rate parallel optic transceivers, MTP ® /MPO transceiver interface connectors, turnkey fiber optic breakout cables, and ruggedized MT ferrule-equipped I/O connectors—circular and rectangular.

High-speed, high data rate board-to-board stacking connectors

1 Card-to-card optical flex circuits 2 Shuffle circuits

3 On-board optical flex circuits 4 Optical backplanes

Hybrid I/O connectors (Rugged MT ferrule, discrete termini, and expanded beam)

Vita 66.1 and 66.4 and Glenair Signature optical backplane connectors

Optical flex MT breakouts to optical backplane or I/O connector

Rectangular MT I/O and board connectors

Available Prizm® expanded-beam ferrules from US Connec

MT interface connector-

equipped parallel optic transceivers

OPTICAL FLEX TRANSCEIVERS

High-Density MPO/MTP ® Fiber Optic Interconnect

DataStar SPACE parallel optic transceiver modules with: Radiation lot acceptance testing (RLAT) Group C lot traceability ASTM E595 outgassing Heavy ion, gamma, proton radiation resistance

0500-3060 DataStar™ SPACE Quad Parallel F/O Transceiver

DataStar MIL-AERO parallel optic transceiver modules with: Aerospace-grade: -40°C to +100°C High-shock and vibration tolerant Secure PCB mounting and host board interconnection CDR (Clock Data Recovery) option available for 25Gbps and 28Gbps

0500-3023 DataStar™ MIL-AERO Quad Parallel F/O Transceiver

QwikConnect • July 2022

SPACE AND MIL-AERO GRADE MT Fiber Optic Connectors FOR USE WITH OPTICAL FLEX CIRCUITS

Up to 24 fibers in a single compact, lightweight ferrule

Ruggedized I/O connectors optimized for use with high-density MT ferrule optical flex

Mated pair of high-density Series 79 MT connectors—the smallest and lightest ruggedized MT assembly in the industry. Note the use of Optical Flex on the I/O receptacle side, and round environmental cable on the plug side

Lightweight, small form-factor MT fiber optics in Glenair Signature SuperNine ® and Series 79 connectors: The aerospace-grade I/O connector solution for use with Glenair parallel optical transceivers and MT optical flex circuits TWO STYLES OF HIGH-DENSITY MT FERRULES SUPPORTED: STANDARD MT PHYSICAL CONTACT FERRULE AND LOW-LOSS PRIZM® LENS EXPANDED BEAM

Small form-factor, high- density MT fiber optic solutions for rugged space and mil-aero applications Optimized for use with parallel optic transceivers and optical flex circuitry Singlemode, multimode and specialty fiber including radiation-tolerant for space applications Temperature tolerance from -40°C to +85°C Designed for optimal low insertion loss performance in high vibration and shock environments IP67 Environmental sealing , IP68 available at interface

Both ferrule styles are easily inserted with common tools, and may be equipped with an engineered spring member for precise axial alignment in high vibration and shock applications.

QwikConnect • July 2022

GLENAIR

SPACE AND MIL-AERO GRADE MT Fiber Optic Connectors FOR USE WITH OPTICAL FLEX CIRCUITS

CIRCULAR AND RECTANGULAR

Ruggedized MT I/O Connectors

Plug with EMI/RFI ground spring Shell size-insert arrangement 11-1, Up to 24 fibers (1 MT ferrule)

In-line receptacle Shell size-insert arrangement 13-2, Up to 48 fibers (2 MT ferrules)

Panel-mount receptacle Shell size-insert arrangement 15-3, Up to 72 fibers (3 MT ferrules)

Jam nut receptacle Shell size-insert arrangement 17-4, Up to 96 fibers (4 MT ferrules)

Single-ferrule MT Series 79 plug up to 24 fibers

Single-ferrule MT Series 79 receptacle up to 24 fibers

Dual-ferrule MT Series 79 plug up to 48 fibers

Dual-ferrule MT Series 79 receptacle up to 48 fibers

VITA 66.1 AND 66.4 MT FERRULE RUGGED OPTICAL BACKPLANE CONNECTORS FOR VPX BACKPLANE APPLICATIONS

VITA 66.1 and 66.4 spec compliant for use with optical backplanes Integrated alignment pins Glenair designed spring-loaded MT ferrules Supports industry standard MT ferrules—up to 24 channels per MT No unique tooling required for assembly IDEALLY SUITED FOR Embedded computing devices

Right-angle configurations for motherboard to daughtercard applications

Mlitary aircraft (Phased Array) Radars Flight computers and other aircraft LRUs Command center comms equipment

QwikConnect • July 2022

FLEX, RIGID FLEX, AND RIGID PCB ASSEMBLIES Rectangular PC-Tail Connectors SHORT LEAD-TIME, IN-HOUSE MANUFACTURED

SERIES 28 HIPER-D M24308 HIGH-PERFORMANCE ENVIRONMENTAL PCB CONNECTORS

280-024 right-angle PC tail pin connector

280-025 right-angle PC tail socket connector

280-023 straight PC tail socket connector

280-022 straight PC tail pin connector

280-026 straight PC tail pin connector, low-profile

280-027 straight PC tail socket connector, low-profile

280-028 right-angle PC tail pin connector, low-profile

280-029 right-angle PC tail socket connector, low-profile

280-051 combo straight PC tail socket connector

280-050 combo straight PC tail pin connector

280-052 combo right-angle PC tail pin connector

280-053 combo right-angle PC tail socket connector

280-055 combo straight PC tail socket connector, low-profile

280-056 combo right-angle PC tail pin connector, low-profile

280-054 combo straight PC tail pin connector, low-profile

SERIES 79 HIGH-PERFORMANCE MICRO-CRIMP ENVIRONMENTAL PCB CONNECTORS

790-028 straight PC tail panel receptacle

790-043 straight PC tail free-standing receptacle

790-029 straight PC tail panel plug

790-044 straight PC tail free-standing plug

790-042 Right angle PCB panel-mount hybrid coax

QwikConnect • July 2022

GLENAIR

FLEX, RIGID FLEX, AND RIGID PCB ASSEMBLIES Rectangular PC-Tail Connectors SHORT LEAD-TIME, IN-HOUSE MANUFACTURED

ALPHALINK • SERIES 791 • SERIES 792 HIGH-PERFORMANCE RECTANGULAR PCB ENVIRONMENTAL CONNECTORS

171-134 AlphaLink SL connector with spring-loaded contacts

GSTT-PF HD Stacker top-of-stack flex

GTBA/GTBB-SF MIL-DTL-55302 type flex vertical PCB

791-015/-011 Series 791 straight and 90° scoop-proof panel-mount with grounding fingers

792-006/-010 Series 792 Straight and 90° high-speed El Ochito

MIL-DTL-83513 MICRO-D AND HIGH-SPEED MICRO-D ENVIRONMENTAL PCB CONNECTORS

MWDM-B MWDM-BR vertical and 90° mount thru-hole PCB

MWDM-CBS MWDM-CBR vertical and 90° mount thru-hole condensed PCB

GMR75 GMR75C Condensed board, .075" pitch vertical and 90° PCB

GHS4-M VersaLink high-speed Micro-D right angle PCB

GHSM-HBR High-Speed Micro-D right angle PCB

MIL-DTL-32139 NANOMINIATURE AND GMMD ENVIRONMENTAL PCB CONNECTORS

890-006/-007 single-row vertical PCB plugs / receptacles

890-008/-009 single-row right angle PCB plugs / receptacles

891-006/-007 dual-row vertical PCB plugs / receptacles

891-008/-009 dual-row right angle PCB plugs / receptacles

GMMD high-speed micro with nano TwistPin contacts

HERMETIC RECTANGULAR GLASS-TO-METAL SEAL PCB CONNECTORS

790-066 Series 79 hermetic PCB connectors

280-012H HiPer-D hermetic PCB connectors

177-140H Micro-D solder-mount hermetic PCB connectors

177-705H Micro-D rear panel-mount hermetic PCB connectors

QPL-M24308/9 D-Subminiature straight thru-hole PCB hermetic

QwikConnect • July 2022

FLEX, RIGID FLEX, AND RIGID PCB ASSEMBLIES Circular PC-Tail Connectors SHORT LEAD-TIME, IN-HOUSE MANUFACTURED

SUPERNINE® D38999 SERIES III ENVIRONMENTAL PCB CONNECTORS

233-207 flush-flange receptacle

233-208 stepped contact receptacle

233-209 short standoff receptacle

233-210 threaded standoff receptacle

233-211 dual flange receptacle

SUPERNINE® D38999 SERIES III ENVIRONMENTAL PCB SPECIALS

233-218 high-speed hybrid with threaded standoffs

233-217 high-speed jam nut with El Ochito® contacts

240-383D dual-flange wall-mount EMI filter connector

050-335 opto-electronic jam nut with threaded standoff

257-859 PCB receptacle with compliant pin contacts

SUPERNINE® D38999 SERIES III GLASS- AND LIGHTWEIGHT ENCAPSULANT-SEALED PCB HERMETICS

233-100-H2 box mount receptacle

233-100-H5 solder mount receptacle

233-100-H7 jam nut mount receptacle

233-254 high-speed hermetic jam nut receptacle

233-250 CODE-RED lightweight hermetic jam nut receptacle

MIL-DTL-38999 SERIES I, II, III, AND IV QPL GLASS-SEALED PCB CONNECTORS—CLASS N, Y, AND H (SPACE-GRADE) HERMETIC

231-100-H0, H7, H5 Series I scoop-proof bayonet

232-100-H0, H2, H5, H7 Series II low-profile bayonet

233-100-H2,-H5,-H7,-H8 Series III triple-start

234-100-H2, H7, H5, H8 Series IV scoop-proof breech-lock

QwikConnect • July 2022

GLENAIR

FLEX, RIGID FLEX, AND RIGID PCB ASSEMBLIES Circular PC-Tail Connectors SHORT LEAD-TIME, IN-HOUSE MANUFACTURED

SERIES 80 MIGHTY MOUSE MICRO MINIATURE ENVIRONMENTAL PCB CONNECTORS

Series-801 double-start thread

Series-803 bayonet-lock

Series-804 push-pull QDC

Series-805 triple-start

Series-800 UN thread

SERIES 88 SUPERFLY AND M32139-TYPE NANOMINIATURE CIRCULAR ENVIRONMENTAL PCB CONNECTORS

SuperFly 880-041R-•-880-037R QDC vertical and 90° receptacle

SuperFly 881-019R-•-881-020R threaded vertical and 90° receptacle

Nanominiature 893-008-•-893-009 breakaway and threaded straight

Nanominiature 893-010-•-893-011 breakaway and threaded right-angle

SERIES 806 MIL-AERO MICRO MINIATURE ENVIRONMENTAL PCB CONNECTORS

806-021-•-806-022 Environmental

806-058 High-frequency coax

806-039-•-806-040 High-speed El Ochito

240-806-21 EMI/RFI filter

806-025, -026 glass 806-028,-043 lightweight Hermetic

SUPERSEAL RJ45 / USB ENVIRONMENTAL PCB CONNECTORS

QwikConnect • July 2022 MIL-DTL-38999 Sr. III SuperSeal

Series-80 Mighty Mouse SuperSeal

Series-IPT 26482 type SuperSeal

Series-ITS 5015 type SuperSeal

MIL-DTL-28840 SuperSeal

POINT-TO-POINT AlphaLink ® SL Flex Jumpers RUGGED I/O TO SPRING-PIN CONTACT FLEX ASSEMBLIES

AlphaLink® SL flex jumpers: Compact point-to-point assemblies that combine lightweight flex circuitry with Glenair signature I/O and board-level connectors. These turnkey jumper assemblies reduce system size and weight while accelerating assembly qualification and test of aerospace avionics and other mission- critical electronic systems.

Chemically etched, copper- clad polyimide flex circuit jumpers offer excellent temperature tolerance, dimensional stability, and reduced size and weight All designs utilize AlphaLink®SL board connectors with solder-free spring-loaded contacts Glenair small form-factor Mighty Mouse, Micro-Crimp, HiPer-D, and SuperFly I/O connectors Designed for optimal electrical performance, including matched- impedance applications

A high-availability, fast-turnaround catalog solution, Glenair AlphaLink flex jumpers offer superior electrical and mechanical performance compared to conventional wire harnessing

AlphaLink-to-AlphaLink board-to-board flex jumper assembly

QwikConnect • July 2022

GLENAIR

POINT-TO-POINT AlphaLink ® SL Flex Jumpers RUGGED I/O TO SPRING-PIN CONTACT FLEX ASSEMBLIES

POINT-TO-POINT JUMPER SELECTION GUIDE

AlphaLink ® SL Solder-Free I/O-to-Board

Series 89 Circular Nanominiature-to-AlphaLink SL flex jumper with breakaway or threaded I/O coupling in 6 contact arrangements

Series 88 SuperFly-to- AlphaLink SL flex jumper with quick-disconnect or threaded I/O coupling in 7 contact arrangements

Series 801 Mighty Mouse-to- AlphaLink SL flex jumper with double-start ACME thread I/O coupling in 8 contact arrangements

Series 804 Mighty Mouse-to- AlphaLink SL flex jumper with push-pull quick-disconnect QDC I/O coupling in 8 contact arrangements

Series 89 Rectangular Nanominiature-to-AlphaLink SL flex jumper (rear-panel- mount plug or receptacle) in 7 contact arrangements

High-reliability Micro-D MIL-DTL-83513 type rectangular-to-AlphaLink SL flex jumper in 7 contact arrangements

Series 79 Micro-Crimp advanced-performance rectangular-to-AlphaLink SL flex jumper in 7 contact arrangements

Series 28 HiPer-D -to-AlphaLink SL flex jumper (MIL-DTL-24308 intermateable rectangular) in 6 contact arrangements

QwikConnect • July 2022

GLENAIR • Volume 26 • Number 3

Force Multiplier This past week, we hosted a big group at the factory from our field sales force in Europe. In addition to their classroom activities—mostly new product training and Glenair culture sessions—the team enjoyed touring our Southern California factories in Glendale, Arcadia, and Anaheim, as well as face-time with product managers, engineers, and members of the operations team. For most of the group, this was their first opportunity to visit the Glenair headquarters in over two years. During that time, we hosted numerous broadcast and on-line activities from our Glenair TV Studios—the in-house platform we use for monthly updates to the sales team and others. But as many of us observed this past week, there is no substitute for bringing the team to the factory. There is a great deal of mutual respect between our field sales force and the factory team, as both ends of the bench understand the value that the other side brings to the table. And I must say, one of the key ways we maintain this value at Glenair is through regularly scheduled training sessions that expose our field sales force to the people and culture of the factory. There is an old saw about the sibling wine- makers Ernest and Julio Gallo, and the friendly spirit of competition between them. Ernest managed the sales side of the business and reportedly liked to say that his goal was to sell more wine than Julio could make. While Julio countered it was his goal to make more wine than Ernest could sell. We have a bit of this same approach at Glenair, and we do our best to ensure each side in the friendly competition has all the resources needed to meet their responsibilities to keep their area of operation healthy and going strong. This next observation may get into the metaphysical weeds a bit, but I do believe it is true and worth sharing. And that is that this business of bringing the sales force to the factory—in this case all the way from Europe—has the mysterious effect of multiplying their numbers. What do I mean by this? Merely that the size of the force that sits down on day one of the training seems to miraculously expand by the end of the week. We are all familiar with the concept of a force multiplier. A long lever arm for example, leveraged against a fulcrum, provides an individual with the ability to lift a far heavier load than would otherwise be possible. In military applications, a force multiplier is an advantage—such as provided by advanced weaponry—that gives the unit the ability to accomplish far greater feats than would be possible without it. The Glenair STAR-PAN power and data hub is a classic example of a force multiplier, as it allows the guys on the ground to tackle longer missions, with greater safety and mission effectiveness. In other words, it multiplies their force, as if their very numbers were greater. We see the same thing happen when members of the sales team visit the factory. All the knowledge, skills, and company culture they obtain in the process literally multiplies their effectiveness in the field and their ability to provide value and service to our customers. Glenair is committed to knowledge, skills, and affective domain training and development. We believe it is one of the key ways we ensure our organization is well positioned to meet the complex challenges of our mission- critical interconnect business.

Publisher Christopher J. Toomey Managing Editor Marcus Kaufman Art Director/Editor Mike Borgsdorf Graphic Designer George Ramirez Editor Meghan Taylor Technical Consultant Jim Donaldson Issue Contributors Scott Meloche Indy Murillo Mathias Nataksui Greg Noll Tom Pfingston Ben Porcaro

Chris Van Soest Distribution Terry White

To subscribe or unsubscribe, please contact Terry White: twhite@glenair.com

QwikConnect is published quarterly by Glenair, Inc. and printed in the U.S.A. All rights reserved. © Copyright 2022 Glenair, Inc. A complete archive of past issues of QwikConnect is available on the Internet at www.glenair.com/ qwikconnect

GLENAIR, INC. 1211 AIR WAY GLENDALE, CA 91201-2497 TEL: 818-247-6000 FAX: 818-500-9912 E-MAIL: sales@glenair.com www.glenair.com

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