The demand for high-density electronics in defense technology is growing, driving innovations in flexible circuit designs. Bob Stanton, Director of Technology at Omnetics Connector Corporation, explores how flexible circuits are helping meet the needs of rugged, portable systems in military and defense applications.
Flex Circuit Technology for High-Density Electronics
Flexible circuit designs have been a trusted solution for over 50 years, but their role is expanding as the need for compact, high-performance electronics increases in defense technologies. With the rise of portable communication devices, autonomous robotics, and multispectral imaging systems, rugged and efficient circuit solutions are critical.
These circuits allow for the development of miniaturized, high-speed chips that can handle the complex needs of modern military systems. Multispectral and hyperspectral imaging technologies, which require processing massive amounts of data, rely on flexible circuits to support faster data transmission and higher frame rates, from 30 frames per second to over 100 frames per second.
This increase in processing speed drives data rates beyond 10 gigabits per second, pushing the boundaries of cable and connector designs necessary for transmitting high-quality signals to processors and storage units.
As technology evolves, flexible circuits enable the use of advanced imaging systems for defense, such as infrared and hyperspectral imaging, which are vital for tasks ranging from security scanning to geospatial mapping.
The ability of these circuits to function in demanding environments makes them ideal for military applications, where portability, durability, and data integrity are critical. They can be found in Cube Satellites and in the latest myoelectric sensors used in advanced prosthetics, offering lightweight, rugged solutions for a wide range of defense technologies, such as:
- Highly portable communication and tracking devices
- Autonomous robotic devices
- Drones with multispectral imaging payloads for geospatial mapping
- LIDAR positioning and ranging devices
- Highly portable antenna systems offering multiple beam frequencies and pulse amplitude sensing within the same units
Advantages of Flex Circuits
Flex circuits are essential for space-constrained and high-performance environments.
In rugged defense environments, the reliability of connectors used in flexible circuits is crucial. Military-grade connectors, such as Mil-Standard 83513 Micro-d and Mil-Standard 32135 Nano-d, are designed to withstand the extreme conditions often encountered in military operations, including wide temperature ranges and physical shocks.
These connectors ensure that flexible circuits maintain their performance in the field, providing consistent, high-speed signal transmission essential for mission-critical tasks. Flexible circuits and their connectors must also handle frequent mating and de-mating, making durability a key consideration in their design.
Designers of flexible circuits for defense applications have access to a variety of connector options, allowing for customized solutions that meet the specific needs of each project.
Military and space-qualified materials are used to ensure that connectors not only fit physically, but also meet performance standards required for high-speed signal transmission and data processing.
These circuits offer:
- Bendable polymer layers with copper conductors to optimize flexibility and ruggedness
- Multi-layer designs that allow for higher density and faster signal propagation
- Heat dissipation technology to manage the heat generated by high-speed data processing
- EMI shielding for enhanced signal integrity, crucial in defense electronics
The resurgence of flexible circuit technology is addressing the needs of modern defense systems, offering solutions for high-speed data transfer, compact design, and rugged reliability. As defense electronics become more sophisticated, flexible circuits and military-grade connectors will continue to play a vital role.
For more details on how flex circuits are transforming defense electronics, read the full article “The Return of Flex Circuit Connections for Rugged, High Density Electronics” on the Omnetics Website >>