SWaP-Optimized Solutions for the Future Soldier

By Contributed Article | February 25, 2025

For survivability and operational efficiency, gear that is lightweight and relatively easy to carry is a necessity. Miniaturized connectors help meet these goals.

The term “future soldier” was developed in the 1990s to describe combat soldiers outfitted with high-tech uniforms and equipment on the battlefield. While the term was once futuristic, it depicts what is taking place now and will develop further in line with military strategies. To keep up with the progressive era of soldier modernization, reliable and rugged connectors are required to ensure effective and safe operations. Therefore, SWaP-optimized connectors are at the forefront of body-worn equipment. SWaP stands for size, weight, and power.

Combat troops must be able to move quickly to protect themselves from danger. For survivability and operational efficiency, gear that is lightweight and relatively easy to carry is a necessity. With these considerations, connectors used in these devices must be small in size and weight. However, size and weight must not impact operating performance.

“SWaP connectors allow engineers to simplify board layouts and shrink the existing footprint without decreasing functionality,” said PEI-Genesis product specialists in the blog article, SWaP-Optimized Connector Solutions for Military Aerospace Applications. “These connectors make it possible to create shorter, more direct interconnections that allow for faster signals and response times. And because they are small connectors, vibration is reduced, leading to greater stability.”

While size and weight are important, many other factors play into system designs intended for harsh military environments. Seamless functionality of military equipment is paramount and connectors play a vital role in maintaining optimal performance under challenging conditions, which could include dust, sand, water submersion, or water ingress. Additionally, as soldiers’ equipment relies on numerous peripherals for secure data and signal transfer, robust shielding becomes imperative to safeguard against radiated emissions, interference, or security breaches. The connectors must support high-speed data, signal, and power transmission, ensuring troops stay continuously connected, making informed decisions, and responding swiftly to dynamic situations. The integration of these features into military-grade connectors enhances overall efficiency and effectiveness, contributing significantly to the success of military operations.

Tactical vests are a key component of soldier-worn equipment. They are designed to be worn over the torso with several devices attached to protect soldiers with enhanced combat capability. They permit soldiers to carry essential gear, ammunition, communication devices, and other mission-specific equipment, allowing them to react quickly and effectively in combat. They are equipped with GPS devices, radios, remote receivers, all with a need for reliable connections.

From tactical vests to modern helmets, soldier worn equipment is advancing.

Modern helmets have integrated night vision capabilities, communication systems, and heads-up displays (HUDs) to provide real-time information about the battlefield for increased situational awareness. This allows soldiers to gather intelligence, maintain communication with their unit, and make informed decisions while staying protected.

Soldier-worn product solutions

In addition to SWaP considerations, connectors for soldier-worn applications require features such as durability, ingress protection, EMI shielding, and other harsh environment protections.

Amphenol Ltd. Stingray 7 Series magnetic connectors feature compact size, low profile, and durable metal shell. Engineered to endure challenging conditions with exceptional resistance to moisture, dust, dirt, and chemical exposure. This series has an IP68 rating, withstands significant vibration and shock, supports over 10,000 mating cycles, operates within a wide temperature range (-55 °C to +85 °C), and provides 360° EMI shielding. Self-alignment and a 60° rotatable design allows these connectors to sit flush against the body, preventing any snagging or potential damage. Their quick disconnect feature facilitates seamless connections between non-tethered equipment, such as helmet to torso, and allows for blind mating.

Future Soldier Solution Specs

ITT Cannon’s HDx Series offers a reliable small form factor interconnect solution in a lightweight, compact design with ultra-high-density layouts to enable critical USB, HDMI, or Ethernet high-speed data transmission. This portfolio focuses on military soldier-worn technology and supports medical, communications, and industrial markets. Its specific applications include military ground vehicles, factory automation, and robotics. The lightweight technology of the HDx Series is essential for soldiers who must carry this equipment on their bodies (i.e., helmet systems, weapon systems, tactical vest systems). In addition, it supports 5,000+ mating cycles, has a 20-meter sealing depth when mated, and is rated for an operating temperature of -51 °C to +125 °C. The series is available in a breakaway or screw-lock breakaway coupling style and an anti-glare, non-reflective Ruthenium plating.

2M Series from Amphenol is a micro-miniature and lightweight connector, specifically tailored for soldier-worn equipment. It features the 2M801 series, Amphenol’s DualStart ACME threaded coupling mechanism to eliminate the risk of accidental disconnection in environments with intense vibrations. Tri-start ACME thread, push-pull, and bayonet coupling options are available. Stainless steel and several aluminum platings make them a versatile and corrosion resistant. The shell plating comes in zinc-nickel with black chromate, contributing to the all-black camouflage essential for stealthy night operations. The 2M Series surpasses the stringent D38999 specifications for vibration and shielding, while being 72% lighter and 52% smaller compared to standard D38999 connectors.

Soldier-worn equipment provides essential protection, enhances combat capabilities, and increases a soldier’s overall effectiveness and survivability on the battlefield. These technologies are a critical component of modern military operations, enabling soldiers to carry out their missions with confidence and resilience. Reliable and ruggedized connectors allow these systems to operate effectively in even the most demanding environments.

Article contributed by the Mil/Aero Product Team at PEI-Genesis.

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