Magnetic Wearable Connectors for Harsh Environments

By Noah Levine | April 01, 2025

Magnetic soldier wearable interconnects meet the unique demands of military personnel and equipment. Designed for critical mission success of field decision makers, these connectors offer seamless interoperability and reliable performance across military units.

Amphenol PCD’s Gladiator is specially designed for soldier-worn applications, including data sharing, battery charging, and peripheral connectivity. The rectangular wearable connector can be adopted by search and rescue personnel and first responders. Along with panel mount capabilities for Vehicle and drone integration.

Introducing a new product development in magnetic soldier wearable connectors: A small, lightweight, flat connector specifically designed for soldier-worn applications, including data sharing, battery charging, and peripheral connectivity. A leading solution in the market, magnetic soldier wearable interconnects meet the unique demands of military personnel and equipment. Specifically designed to ensure critical mission success of field decision makers, these connectors offer seamless interoperability and reliable performance across military units.

Magnetic wearable connectors align the plugs and receptacles on the soldier and are engineered to fit seamlessly through MOLLE loops, making it adaptable to tactical gear. The mating assembly can be panel-mounted, clipped into MOLLE webbing, or sewn into place, offering flexibility in integration.

Magnetic soldier-worn connector, Gladiator, creates significant value for operators by offering consistent blind-mating through quick connection and disconnection in life-or-death scenarios.

As part of a product range extension, a next generation model introduces a multi-angle release system (sheer force). Complimentary to the high-tech soldier connector, E-textile termination capabilities enhance the functionality of the interconnect in the form of a flat, flexible, soldier worn cable. An addition of the E-textile cable provides durability and ease of use. Overall, the customizability of magnetic wearable connectors allows the solution to adapt to specific needs in critical environments, ensuring optimal performance in military scenarios.

Magnetic wearable connectors create significant value for operators by offering consistent blind-mating through quick connection and disconnection in life-or-death scenarios. Traditional connectors often overlook key human factors such as comfort, ease of use, and practicality. These magnetic wearable connectors are designed to be waterproof (mated and unmated), lightweight and offer an ideal touch temperature. Featuring a low-profile with a first mate, last break mechanism, usability is improved in high stress environments. The low-profile of the mated pair sits only half an inch off the body to reduce snagging. The wearable interconnect’s longevity is increased with a secure connection that prevents pin bending.

Amphenol PCD’s Gladiator and MARS Gladiator offer 180 degrees mating capabilities. The plugs and receptacles on the soldier fit seamlessly through MOLLE loops. The addition of the Molliflex e-textile cable provides durability and ease of use in vigorous military environments.

The development process for magnetic wearable connectors is broken into three segments.

Step 1: Understand the specific program applications and its intended use. With blind-mating and a low-profile, magnetic wearable connectors are ideal for field operator’s body and kits. Prior use cases and customer solutions are identified to determine whether the magnetic wearable connector will be a new concept, a spinoff, or an adaptation of existing technology. The focus is always on delivering the most cost-effective connector and quickest solution while considering the scope of innovation.

Amphenol PCD’s MARS Gladiator is the next generation model which introduces a multi- angle release system (sheer force).

Step 2: Complete prototyping and testing. With NPI (new product introduction) quick-turn solutions in mind, the next step involves collaborating with design engineers to understand their needs and how the wearable connector can fit into their application. During this phase, market expertise from the wearable tech industry is essential to find the perfect combination of function, form, and design. “Form-fit-function” wearable connector prototypes are created for initial integration and soldier feedback, focusing on the design rather than electrical functions within a two-week period. After gathering end-user feedback, modifications are made to improve the wearable connector.

Amphenol PCD’s Gladiator– a magnetic soldier-worn solution, ensures critical mission success of field decision makers within the Armed Forces.

Step 3: Incorporate electrical functions and conduct thorough testing. This leads to a fully refined product that is ready within an 8-week timeline from start to finish.

Measuring the metrics and success criteria for magnetic soldier wearables consists of military personnel feedback, market performance in vigorous conditions, and the ability to meet specific field operator requirements. The goal for magnetic wearable interconnects is widespread industry adoption, meaning the targeted audience expands beyond NATO forces and the U.S Army to search and rescue individuals and first responders. Performance is another indicator of success. For instance, Special Operation forces have different requirements than the general infantry, with an emphasis on ensuring the connectors meet ruggedized standards such as MIL-STD-810G, a crucial standard in ensuring durability and reliability in extreme conditions.

Amphenol PCD’s Gladiator is IP68 rated mated and unmated, lightweight and offers an ideal touch temperature sitting only half an inch off the body to reduce snagging.

Success is also dependent on mated and unmated connections. Different harsh environment specifications, such as exposure to water may not apply to all scenarios. With each application having its own set of requirements, engineers collaborate with the end customer’s engineering department to develop optimal solutions for each military use. The compatibility of magnetic wearable connectors across many forces, such as the ability for a U.S. Army soldier to plug into a UK Allied force system with the same interface, is another indicator of achievement. This example demonstrates versatility in global military operations.

Magnetic wearable connectors are a revolutionary solution for soldier-worn applications, with the potential to expand beyond soldiers. As a small, lightweight, versatile wearable connector, data sharing, battery charging, and peripheral connectivity is met in the trying conditions soldiers face in the line of duty. Enhanced by E-textile cables for superior durability and ease of use, wearable magnetic quick disconnects stand out in the market for their customizable options while delivering form, fit, and function tailored to the unique needs of military personnel. With few competitors offering reliable and adaptable wearable solutions for field operators, magnetic soldier-worn connectors are a competitive choice for optimizing performance in the military industry.

To learn more, visit Amphenol Pcd.