Behind the lines:
how ODU develops connectors for military missions

Simon Köhler, product manager at ODU talks about what really matters when it comes to military connectors, how standards and special solutions differ - and which technological trends could determine the future

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In modern military applications, reliability, robustness and efficiency are decisive for success during missions. With portable power supply solutions, such as Soldier Battery Packs, every contact counts — literally. Connectors not only have to transmit high currents, but also withstand extreme environmental conditions: from Arctic cold to salt water and dust.

An established standard in this area is STANAG 4695, which is widely used in the USA and NATO countries in particular. ODU provides a suitable solution with the ODU AMC® NP - and even goes one step further with the ODU AMC® High-Density.

Q: What are the most important requirements for connectors in military applications?

A: As a former soldier, I know every second counts during a mission, and every mistake can have serious consequences. A unit is only as strong as its weakest link. That is why our connectors must function reliably without compromise. They must be robust and easy to operate, and they must provide reliable data and power transmission. As a manufacturer, our job is to ensure that users do not have to worry about technology on the battlefield. The connection simply has to work at all times. We provide safety where mistakes are not an option.

Q: Why is power transmission so critical for portable soldier systems?

A: The power supply is the backbone of all electronic functions, including communication, navigation, reconnaissance and weapon systems. If the power supply fails, an individual soldier or even an entire unit is, in effect, blind. There is then a lack of perception, orientation and the ability to act. Therefore, particularly in combat conditions, power transmission must function reliably, even when moving, and without loss, when it is cold, wet and dirty. This is not about comfort, but functionality in an emergency. The connectors directly impact usability and safety.

Q: What distinguishes the NATO-STANAG 4695 especially for military missions?

A: NATO STANAG 4695, also known as the Nett Warrior Connector, defines a standardized interface for portable soldier systems. This ensures a high level of compatibility between equipment from different manufacturers. This is particularly advantageous for multinational operations. The standard establishes a clear framework and promotes interoperability within NATO. However, every standardization has its limits, especially in extreme operating conditions, such as Arctic temperatures below -40°C. Many systems reach their limits in these conditions.

Q: The ODU AMC® High-Density offers impressive technical data - for which applications is this connector particularly suitable?

A: The AMC High-Density was specially developed for compact, portable systems. Its small size makes it ideal for "body-worn equipment," such as radios, night vision technology and modern battery units. The goal is to make equipment as functional and lightweight as possible. The AMC HD reduces weight and size while offering a higher current carrying capacity of up to 10 A. It can withstand dives of up to 20 meters, offers up to 5,000 mating cycles, and operates reliably in temperature ranges from -51°C to +125°C. These features make it ideal for applications with high performance and environmental resistance requirements.

Q: In which scenarios does it make sense to rely on a non-standardized solution such as the AMC High-Density?

A: Whenever maximum robustness, miniaturization or higher data and power transmission are required. In specialized applications, such as modernized guidance and reconnaissance systems, the flexibility of the AMC High-Density can be crucial. In addition to standard power connections, the plug supports interfaces such as USB, HDMI and DisplayPort, opening up new possibilities in system architecture. When it comes to future requirements, it is often worth taking the step away from the standard and toward a customized solution.

Q: How do extreme environmental influences such as cold, water or salt water affect the performance of connectors?

A: These influences are a real challenge: Cold can make materials brittle and impair the flexibility of the seals. Water - especially salt water - promotes corrosion and can attack the electrical insulation. Dust and dirt make handling in the field even more difficult. All this can lead to contact problems or even total failure. That's why we develop our connectors so that they function reliably even under the most extreme conditions - waterproof, dirt-resistant and corrosion-protected. Because if a plug fails, the entire system can become unusable - with potentially life-threatening consequences.

Q: What test procedures does a military connector undergo at ODU to meet the requirements?

A: Our connectors undergo an extensive testing program. This includes salt spray tests for corrosion resistance, as well as vibration, shock, dust and sand tests, and high-current and high-voltage tests. In our in-house laboratory, we use microsections to analyze the quality of the electroplated layers and ensure maximum durability. We also perform tests according to military standards, such as MIL-STD-810 and MIL-DTL-38999. These inspections simulate realistic operating conditions and provide our customers with peace of mind knowing that our products will perform well in an emergency.

Q: How strong is the influence of new technologies on the requirements for connectors in soldier-worn systems?

A: The digitalization of the battlefield has changed the requirements significantly. Modern soldier systems require a stable power supply and powerful data connections for real-time communication, sensors, tactical networks and more. This means: connectors must be mechanically robust and able to transmit high data rates loss- and interference-free. At the same time, size must not increase. This is an enormous technical challenge that we address with innovative designs and high-quality materials. The future belongs to intelligent, multifunctional connectors that reliably combine power, data and signals — even under the harshest conditions.

Specification	STANAG 4695	ODU AMC® High-Density
Outer Ø	Ø18.6mm	Ø13.2mm
Max. Current	5 A	10 A
Protection class	IP 68	IP6K9K
Temp. Range	-18°C to 71°C	-51°C to 125°C
Mating cycles	2000	5000
Salt spray resistance	2x24h	96h
Colour coding	No	Yes
Locking	Break-away	Break away; Screw-Lock

For more information please visit:
https://www.odu-connectors.com