Micro D cable assembly

Ultra-compact micro d cable assembly solutions designed for various sectors.

High-density Micro D-Sub Connector technology with shielded, overmolded designs.

Custom micro d cable assemblies tailored with robust backshells and strain relief.

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Micro D-Sub connector - 1.27mm pitch

Micro D-Sub Connectors are small D-sub connectors with 1.27 mm pin spacing and a micro D cable assembly. It is about a third the size of a regular D-sub, but it can hold 9, 15, 25, or even more contacts in a small space. These high-density connections save space and weight when used in electrical systems. Micro D connectors are very reliable for mission-critical applications because they meet MIL-DTL-83513 standards. They are built to last and have gold-plated contacts. Engineers use them in satellites and drones, among other things, when size and weight are important. Micro D assemblies are very small, but they have a lot of useful features, like solder-cup terminations, PTFE-insulated wires, and the option to shield them with backshells. This connection meets UL standards and will last for ten years or more. It has small dimensions and proven D-sub performance.

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Custom Micro D-Sub connector for application

Our company makes Micro D-Sub connections just for you. Our engineering team can change the number of pins, cable lengths, and terminations. We make our designs work with any kind of enclosure, whether it's a straight-through or right-angle installation. Assemblies are made with high-quality materials that meet the standards set by the military or industry. These connections use standard cables and long-lasting crimp contacts that meet military standards.

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Drone

The connection is great for UAVs because it is small and light. Lightweight PTFE wires and shielded pairs are two parts that can be added to a custom micro D cable assembly for drones. This means that there is less drag and less interference from the GPS, cameras, and sensors. Using wires with a small pitch and silver-plated conductors makes thin cables more conductive. Even in tight spaces, you can count on these Micro D cables to provide reliable video and command and control connections. Overmolded strain relief and backshells will keep you safe from damage caused by vibrations during flight. The micro D cable assembly can handle thousands of flex cycles while the gimbal is moving because the wire is very flexible.

Radar video device

Micro-D connections work well with devices use video or radar. There isn't much room on small radar boards, but small connection fits perfectly. These assemblies can handle both data lines and power lines. To protect the transmission from radio frequency interference, we offer versions with insulated cables. Imaging tools often have problems with shock and vibration, but the strong case and overmold keep these. A Micro D harness for radar will use fine-gauge wire and PTFE insulation to send high-frequency signals. video equipment can only pick up clear signals if the case is waterproof or has an EMI braid. When you look at everything, micro D cable assembly keeps control and video signals stable even in radar gear.

Millitary spec

We promise that our Micro D assemblies will meet or exceed the reliability standards set by the military. We sell connectors that have more than 2000 mating cycles, gold plating, and are MIL-DTL-83513 qualified. Testing assemblies involves putting them through extreme conditions like shock, salt spray, and high G-forces. This cable jacket meets the requirements of both UL and MIL-STD-22759. Metal casings and overmolded strain reliefs to reduce vibrations even more. For military-grade orders, we make sure that every micro D cable assembly passes both burn-in and visual inspections. Because our procedures and materials are better than what is required in aerospace, QL-Custom harnesses are used in defense avionics, missiles, and warfare gear.

Custom Micro D-Sub connectors

DB-25

DB-25

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DB-25M3-04-11

DB-25M3-04-11

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DB-09M2-04

DB-09M2-04

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DB-15M2-02

DB-15M2-02

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DB-09F2-04

DB-09F2-04

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DB-15F2-02

DB-15F2-02

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DB-25F2-02

DB-25F2-02

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DB-15M3-05-11

DB-15M3-05-11

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Micro D sub connectors materials recommendation

A material strategy with durable shells, PA6/PA66 + Fiber insulator, and golden plated pins ensures Micro-D cable assemblies deliver reliable signal integrity and robust performance in demanding conditions.

Hook up wires

Insulator

CNC shell

CNC or stamped pins

Silver plated wires for small picth

For fine-pitch connectors like micro D cable assembly, silver-plated copper wires are common. Silver plating on copper gives the best conductivity and reduces contact resistance. It also protects the copper from corrosion, extending cable life. In micro cables, we use silver-plated strands down to AWG 30 or 32. These strands stay very flexible and can carry a signal without heating up. The silver layer actually increases ductility, so the wire can bend millions of times without breaking. Additionally, silver is slightly more heat-resistant than bare copper, so plated wires tolerate soldering and field temperatures better.

PA6/PA66 + Fiber insulator

The insulator material for Micro-D connectors must be very stable. We often use polyamide (nylon 6/6) or similar plastic, typically fiber-reinforced. Glass-filled PA66 resists high temperatures and has excellent mechanical strength. It keeps contacts precisely spaced at 1.27mm and withstands shock or heat. In some space-grade connectors, LCP (liquid crystal polymer) is used instead for even higher thermal performance. Whether nylon or LCP, the insulator is molded with tight tolerances. It prevents any shorting between pins and withstands soldering and insertion forces.

Machined shell

Our Micro-D connector shells are machined from solid aluminum for precision and strength. Machining yields very accurate dimensions, ensuring the shell halves mate perfectly. After CNC-machining, we plate the shell. A typical finish is nickel or tin plating for corrosion resistance; some custom shells use gold flash on nickel. The plating also improves grounding. Glenair notes its micro-D shells are machined from aluminum. We have both "shell & clamp" style and one-piece machined shells, depending on micro D cable assembly needs. Machined shells can also include integrated strain relief features.

Machined golden plated pins

For maximum reliability, we use gold-plated pin contacts. In our high-end connectors, each pin is cut from a copper alloy and then gold-plated per MIL standards. Gold plating lowers contact resistance and prevents corrosion. Our assemblies use similar contacts for both pins and sockets. Because gold is soft, it forms a strong connection with the mating part. In machined pin designs, the plating thickness is tightly controlled (typically 30 μin of gold over nickel) to withstand thousands of mating cycles. These machined gold contacts minimize signal loss and ensure the connectors perform well even after repeated use and vibration.

Micro D-Sub cable assemblies

Micro D-Sub cable assemblies are small parts that connect electronic devices safely and clearly. They are designed for systems that require strong, steady signals. These cables can carry power, data, and control signals in a very small space. Their tough design helps them handle shaking, bumps, and rough conditions.

PCB mounted connector

PCB-mounted connectors are important parts that link circuit boards to other devices. They help move electricity and data safely and reliably. These connectors come in many sizes and shapes to fit different designs. Their small size helps save space inside electronic products. Strong contact materials help reduce power loss and keep signals clear. Many designs also have locks to stop loose connections. They are easy to place on boards using common soldering methods. They work well for both slow and fast data signals. Their strong build helps them last longer. Because of these features, they are used in phones, machines, cars, and communication equipment.

High density shields

High-density shields help protect electronic parts from noise and unwanted signals. They keep signals clean and easy to read inside small systems. These shields allow many wires to fit into a tight space. Their smart design helps block harmful interference. Strong materials give them long life and solid support. They also help control heat by allowing warm air to escape safely. This will enable devices to work better and last longer. Their small size makes them perfect for tiny electronic products. They are easy to install in modern factories. Because of this, they are widely used in medical tools, planes, phones, and data systems.

For small space application

Small-space applications require parts that are tiny, light, and reliable. These designs aim to make devices smaller without losing performance. Small connectors and cables help fit more parts into less space. They allow builders to add many features in tight areas. Careful building helps keep all parts lined up and working well. Light materials reduce the device's total weight. Good insulation and shielding keep signals clear. Flexible parts make it easier to place wires in tight spots. These designs also help air move and heat escape. Because of this, they are used in wearables, medical tools, small gadgets, and modern machines.

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High-Flex Cable Options

Flexible Stranding

The conductors in our cable assemblies are ultra-flexible, making our Micro-D cable assemblies easy to strand. These withstand millions of bends thanks to Teflon insulation and fine multi-strand construction. Robotic arms and other automated tools can effortlessly flex these high-strand wires without fatigue.

Lightweight Jackets

For the outer layer of lightweight jackets, materials like polyurethane or ultra-flex PVC are good choices because they move well. The wearer can move freely in these jackets because they are both flexible and resistant to grease. A lighter wire is very helpful for drones and wearable robots because it makes the moving parts less stressed.

Optimized Bend Radius

Our Micro D assemblies with high flexibility have the best bend radii and, if needed, spiral shielding. This stops kinking from happening. The cable moves with the scanning probes and camera gimbals.

Dynamic Shielding

Our dynamic shielding technology lets us offer braided shields even in cables that are very flexible. They put extra slack in the shield wires so that they can bend without breaking and still protect against EMI.

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Advanced Engineered Design

Ultra-Compact Design

Micro-D connections are smaller and lighter. Less than one-third the size of a standard D-sub, its pitch is just.050" (1.27mm). Engineers fit more functions into smaller housings via this downsizing.

High Pin Density

You can get a lot of use out of a Micro D shell even in small spaces because it has a maximum of 51 pins. Even with 25 pins, a Micro D is much smaller than older DB connections.

Metal-to-Metal Shield

The metal shells that cover connectors protect them. It meets the standards for electromagnetic interference (EMI) for use in space vehicles.

Lightweight Construction

Lightweight designs are important for satellites and unmanned aerial vehicles (UAVs), and micro-D assemblies help with this. The smaller size makes it easier to move and carry more.

Custom Backshells

Grommets and optional Micro D Backshells connect directly, which makes them custom-made by lowering their profile and bulk. TE Connectivity's integrated backshell cuts down on both the weight and the footprint.

MIL-SPEC Reliability

They follow MIL-DTL-83513, which means they will always work well in high heat and vacuum. Polymers with very high temperature resistance and gold connections are needed for use in space and at high altitudes.

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Advanced Engineered Design

Overmolded Cable Assemblies

Overmolding is a common part of the connector interfaces on our Micro D cables. Overmolding the connection and cable into one part makes them stronger. This built-in housing keeps moisture out and absorbs shocks. Overmolded assemblies are better able to handle tough situations because they provide full strain relief at the cable exit.

Strain Relief Boots

We also offer strain relief boots and backshell clamps to hold the cable jacket in place, in addition to overmolds. The entrance point is a common weak spot, but these fasteners stop it from bending. They lower the tension, which stops vibration from damaging the internal wires and crimp joints.

Vibration Rated

Our assemblies are designed to work even when conditions change. We use glue around pins as an optional part and mil-spec bushings to stop vibration. Because of this, the micro D cable assembly stays firmly connected even when it is shaken and stressed a lot.

Shield Bonding

The strain relief also holds the shell in place with the cable shield braid. Connector shells that are properly bonded can act as Faraday cages, protecting communications from electromagnetic interference (EMI) even in very loud places.

Every step follows ISO rules to make sure each harness is safe and the same.

Customer Reviews

I ordered a custom Micro D cable assembly from QL-Custom. The quality was excellent and the turnaround was very fast. The cables fit perfectly in our UAV project and have been rock-solid so far. I highly recommend this company!

John Smith

John Smith

QL-Custom made a shielded Micro D harness for our new drone design. The service was great; they even helped with the wiring diagram. The cable worked flawlessly in our tests, and the strain relief keeps it from breaking under vibration.

Emily Chen

Emily Chen

We needed a military-grade 25-pin micro D cable. QL-Custom delivered a tough, overmolded assembly with gold-plated contacts. It passed all our MIL-STD tests. Very satisfied with their engineering team and quality assurance.

Michael Brown

Michael Brown

These guys know Micro D connectors! The 15-pin cable harness we got is neatly assembled and shielded. The answer to all our questions was quick, and the final product worked great in our radar system.

Fatima Ali

Fatima Ali

Great experience with QL-Custom. I had unusual length and colors requirements. They even added custom labels. The cable assembly arrived fast and exactly as promised. Five stars for customer service and product!

Carlos Martinez

Carlos Martinez

Our medical device needed a tiny, reliable connector. QL-Custom built us a Micro D assembly with fine wires and overmold. The build quality feels very professional. It has been stable in our lab equipment for months now.

Sophie Dubois

Sophie Dubois

Buy Maximum Quality Product from QL-Custom

Custom's specialty is micro D cable assembly and wire assemblies. We make things under tough conditions and have gotten the ISO 9001 certification. Our experts can help you quickly and give you prices. Some of our main markets are aerospace, defense, healthcare, and telecommunications. From the first prototype to mass production, our top priorities are quality and long-term viability. When you work with QL-Custom, you can expect Micro D cable assemblies that are reliable. You can count on QL-Custom to provide you with reliable and affordable MIL-spec cable assemblies whenever you need them. Our team will handle your Micro D project while you focus on what you do best.

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