High-Power Interconnects and Turnkey Cable Assemblies for Rugged Military and Aerospace Applications

Next-Generation Power Interconnects: The TurboFlex® and PowerPlay™ Ecosystem

The Glenair TurboFlex® and PowerPlay™ ecosystem provides high-power distribution for severe military and aerospace environments. It replaces legacy interconnect designs with ruggedized, high-flexibility components engineered for advanced thermal management and environmental safety.

Technical Performance Attributes

• Crown-Ring Contacts: This contact system consists of pure copper socket tines mechanically secured by an external stainless steel ring. This architecture ensures high-conductivity contact points while maintaining structural tension under high-vibration conditions, resulting in lower insertion forces and optimized contact resistance compared to standard legacy pins.
• Raised Tower Dielectric Architecture: This geometry maximizes creepage and clearance distances across all PowerPlay connector packages to prevent arcing and maintain electrical isolation in high-voltage, high-altitude applications.
• TurboFlex® High-Flexibility Cables: Constructed with rope-lay copper or aluminum conductors, these power distribution cables support tight bend radii and operate at up to 4,500 VAC.
• TurboFlex® Duralectric® Insulation Properties: Jacketed in proprietary Glenair Duralectric™ elastomeric material, the insulation is engineered for harsh-environment longevity. Notable attributes include:
  • Thermal Rating: Continuous operational service temperature range from -110°C to 200°C, with standing excursions up to 260°C.
  • Environmental Resistance: Chemically inert and suitable for continuous immersion in jet fuels, diesel, industrial lubricants, and solvents. It resists extreme UV radiation, ozone, and demanding weather conditions.
  • Safety Standards: Fire-resistant, low-smoke, and completely halogen-free (LSZH), meeting rigorous industry standards for flame toxicity and low smoke indexes.

Turnkey Assemblies and Legacy Integration

Turnkey connectorized or lugged cable assemblies are fully tested and ready for deployment. The PowerPlay ecosystem maintains backward compatibility with legacy architectures, integrating with standard solutions such as MIL-DTL-38999 (SuperNine®) and Series 806 Micro-Miniature interconnects.

Comprehensive Power Distribution Interconnects

Beyond the TurboFlex® and PowerPlay™ architectures, a broad range of additional power distribution solutions are available to support legacy retrofits and special-purpose applications. These variations include Series 970 PowerTrip® high-ampacity circular connectors, and heavy-duty, quick-disconnect reverse-bayonet designs optimized for rigorous mechanical and environmental stresses.

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Complete Dimensional Details and How-To-Order Information for All Glenair High-Power Distribution Interconnect Technologies

	PowerPlay™ High-Power Connectors and Cables A Complete Ecosystem of Lightweight Vibration- and Shock-Resistant Connectors, Contacts, and Cables built in strict accordance with MIL-DTL-38999 Series III Series 973
	TurboFlex® Flexible Power Distribution Cables Ultra-Flexible Power Distribution Cables and Turnkey High-Voltage Cable Assemblies with Glenair Signature Connectors Series 96
	PowerLoad™ High-Power Aircraft Connectors and Cables The Aircraft Industry's most Advanced High-Vibration, High-Temperature Tolerant Power Distribution Interconnect with High-Current Carrying Capacity Crown Ring Contacts and Flexible TurboFlex® Cabling Series 972
	PowerTrip® Connectors Quick-Disconnect, High-Current, Harsh-Environment Power Connectors for Rugged Mil-Aero Applications Series 970
	Super ITS™ – 921 High-Performance reverse-bayonet power connector designed for rapid mating and demating in harsh application environments. Series 921
	Eye-Beam™ Power Robust, singlemode fiber coupler with power levels of at least 20W, stability over temperature, and easy adaptability to different single-mode fiber types and wavelengths.
	SeaKing™ Power Subsea Connectors 1–6.6 kV Connectors for deep sea Oil & Gas primary power junctions. Turnkey pressure-rated subsea cable assemblies available.