Connector-assembly specialist expands MIL-DTL-38999 production capacity

Some of the processes involved in assembling these connectors differ from those required for most other connector types, so PEI-Genesis made the decision to build two new assembly lines dedicated to producing fully qualified MIL-DTL-38999 connectors and related products, all of which are offered with PEI’s standard 48-hour assembly service.

“We were able to set up the new assembly lines very rapidly because we had already established a supply-chain partnership with Amphenol,” commented Tony Houghton, operations manager at the Southampton facility. “This involves very close collaboration between the two organisations and provides a framework for open communication between personnel at every level.”

Specifically, PEI-Genesis and Amphenol were able to share each other’s knowledge of MIL-DTL-38999 assembly techniques and tooling, ensuring that the most efficient processes were used from the outset.
As a result, PEI-Genesis invested in several new items of equipment, including two high-resolution inkjet marking machines, two customised mechanical flow ovens for print curing, and two staking machines for the mechanical retention of the MIL-DTL-38999 connector inserts.

“This investment has enabled PEI-Genesis to increase the Southampton facility’s annual MIL-DTL-38999 capacity from around 60,000 connectors to over 200,000,” said Houghton.

All assembly work is carried out under the company’s ISO 9001:2000 quality system, and every connector undergoes MIL-DTL-38999 Group A testing to ensure 100% mateability.

As well as handling Amphenol’s MIL-DTL-38999 connectors, the new assembly lines will also be used for derivative products such as the Amphe-Lite range of composite circular connectors and the Amphe-EX series of ATEX-approved hazardous-area connectors.