Custom Connector Solutions
Engineered Interconnect Solutions for Unique Applications
Standard connectors do not always fit the mechanical envelope, electrical architecture, environmental requirement or system integration needs of a specialized project.
SINOCONNECTORS supports application-specific connector and interconnect development using existing product platforms where possible and deeper custom engineering when required.
Custom solutions can cover connector structure, contact arrangement, insert layout, shell material, surface finish, mating and locking, PCB termination, cable integration, environmental sealing, high-speed transmission, high-voltage power and optical-electrical hybrid functions.
Why Custom Connector Solutions?
Application-Driven
Design
Development starts from the actual equipment requirement, including installation space, electrical function, transmission type, environment, maintenance method and production target.
Full
Customization
Structure, contacts, inserts, shell, mounting, termination, cable integration and environmental design can be evaluated together as one complete system.
Electrical
Performance
Custom engineering can address signal, power, high-current, high-voltage, high-speed, RF and optical transmission requirements.
Mechanical
Integration
Connector geometry can be reviewed around panel openings, PCB position, cable exit, locking method, blind mating and equipment constraints.
Environmental
Adaptation
Solutions can be evaluated for water-tight, subsea, salt-spray, high-temperature, high-vibration and explosion-protection applications.
Engineering
Support
Engineering review can support concept evaluation, platform selection, design, prototype, testing, optimization and production implementation.
What Can Be Customized?
Connector Structure
Circular or rectangular architecture, shell size, mating and locking method, plug / receptacle form, mounting and special mechanical features.
Contact Layout
Contact count, size, pin / socket arrangement, high-density layouts, mixed-size contacts and power, signal, coaxial, bus or optical combinations.
Interface & Pitch
Contact pitch, alignment, keying, anti-mismating, PCB footprint and application-specific interface geometry can be reviewed.
Shell & Housing
Housing shape, overall dimensions, wall thickness, thread or bayonet geometry, mounting flange, panel opening and rear accessory interface.
Materials & Surface Finish
Aluminum alloy, stainless steel, titanium alloy, aluminum bronze and other compatible materials with passivation, nickel plating or corrosion-resistant finishes.
Termination & PCB Mounting
Crimp, solder, dip solder, straight PCB, right-angle PCB, surface mount and cable termination can be evaluated.
Cable / Harness Integration
Cable selection, wire gauge, pinout, shielding, strain relief, rear accessories, overmolding, sealing and branch harness integration.
Environmental Adaptation
Waterproof sealing, IP67 / IP68, deep-sea pressure, wet-mate, salt spray, corrosion, high temperature, vibration / shock and EMI / RFI requirements.
Custom Connector Types
Custom connector development can begin from an existing product platform or a new application-specific architecture. Connector structure, contacts, inserts, materials, mounting, transmission functions and environmental performance can be evaluated around your equipment requirements.
Custom Circular Connectors
Rugged circular connector solutions for applications requiring multiple contact arrangements, environmental sealing, high-current, high-voltage, high-temperature capability or special locking.
Rugged · Sealed · Special Locking
Custom Rectangular Connectors
Application-specific rectangular connector systems for high-density PCB, cable, rack-and-panel and modular equipment interconnection.
PCB · Cable · Rack & Panel
Micro & Miniature Connectors
Compact connector solutions for space-constrained equipment requiring reduced size, low weight, increased contact density or high-speed transmission.
Compact · Lightweight · High Density
High-Density / Modular Connectors
Configurable connector architectures supporting modular inserts, mixed contact sizes, higher circuit density and multiple signal technologies within one interface.
Modular · Mixed Contacts · Configurable
High-Speed Data Connectors
Custom interconnect solutions for differential, controlled-impedance, RF and application-specific high-speed signal transmission.
Differential · RF · Controlled Impedance
High-Voltage / High-Current Connectors
High-power connector solutions for battery systems, power equipment, energy storage and compact electrical systems requiring higher voltage or current capability.
Power · Battery · Energy Storage
Waterproof / Deep-Sea Connectors
Environmental connector solutions for rain, immersion, marine exposure, subsea pressure and applications requiring water-tight or wet-mate connection.
Waterproof · Subsea · Wet-Mate
Optical / Electrical Hybrid Connectors
Hybrid connector architectures combine electrical power or signal paths with fiber-optic channels in one integrated interconnect interface.
Power · Signal · Fiber OpticAdvanced Customization Areas
Contact & Insert Design
Custom contact count, contact sizes, pin / socket arrangements, mixed-current layouts, coaxial, bus, high-speed and optical contact configurations.
Materials & Surface Finish
Shell materials can include aluminum alloy, stainless steel, titanium alloy, aluminum bronze and other compatible materials with project-specific finishes.
Sealing & Waterproofing
Waterproof sealing, IP67 / IP68 directions, cable sealing, pressure-resistant design and wet-mate architectures can be evaluated.
EMI / RFI Shielding
Metal shells, shielding structures, rear accessories and cable-shield termination can be integrated for EMC requirements.
High-Speed & RF
Differential, controlled-impedance, coaxial, RF and high-speed interfaces can be engineered around required data rate, frequency and cable / PCB architecture.
Power + Signal Hybrid
Power, signal and mixed-current contacts can be combined within compatible connector architectures to reduce interface count and system complexity.
Cable & Overmolding
Custom cable selection, wire gauge, shielding, strain relief, rear accessories, potting, overmolding and environmental cable sealing can be integrated.
Mechanical Locking
Threaded, multi-start threaded, bayonet, push-pull, self-locking, blind-mate and anti-loosening mechanisms can be evaluated.
Special Environmental Design
Projects can be evaluated for high temperature, deep-sea pressure, salt spray, vibration, shock, chemical exposure and other severe operating environments.
Modified Standard vs Fully Custom
Modified Standard Product
- Modify contact layout or contact count
- Change pin / socket configuration
- Modify keying or orientation
- Change shell finish
- Modify cable exit or rear accessory
- Add cable assembly integration
- Adjust termination or mounting arrangement
- Uses an existing proven connector platform
- Lower engineering risk and often lower tooling cost
Fully Custom Connector
- New shell geometry and overall dimensions
- New mating interface
- New insert and contact arrangement
- New locking mechanism
- New PCB footprint or mounting interface
- New cable interface and rear structure
- Special sealing or environmental architecture
- New mixed power, signal, RF or optical architecture
- Designed when standard platforms cannot meet the requirement
Applications & Industry Solutions
Cable harness, fiber-optic and hybrid interconnect solutions can be engineered around the electrical, mechanical and environmental requirements of demanding equipment and infrastructure applications.
Industrial Automation
Machine cable assemblies, control harnesses, power-and-signal integration and custom connector-to-equipment assemblies.
Rail Transportation
Rugged cable assemblies, equipment interconnects and integrated power-and-signal harnesses for transportation systems.
Telecom & Data Networks
Fiber-optic assemblies, high-speed differential cable systems and shielded data harnesses for communications equipment.
Aerospace & Defense
Equipment harnesses, ground-power assemblies, lightweight control wiring, optical interconnects and high-vibration cable systems.
Energy Storage & EV
High-current battery harnesses, power distribution interconnects, control wiring and high-voltage connections between battery packs, PDU and related equipment.
Marine & Offshore
Water-tight harnesses, corrosion-resistant cable assemblies, subsea systems, towing solutions and optical-electrical hybrid interconnects.
Robotics & Precision Equipment
Compact control and instrumentation harnesses for space-constrained equipment requiring precise routing, signal integrity and high-density connectivity.
Test & Instrumentation
Lightweight measurement harnesses, high-density connectors, traceable labeling and signal-integrity focused wiring for test and instrumentation systems.
From Requirement to Production
A proven 10-step process from concept to volume production.
Application
Review
Requirement
Definition
Connector
Architecture
Material &
Contact Selection
Mechanical /
Electrical Design
Prototype
Testing &
Validation
Design
Optimization
Pilot
Production
Mass
Production
Prototype, Validation & Testing
We validate performance, reliability and environmental resistance at every critical stage to ensure your connector meets the most demanding requirements.
Electrical Testing
- Contact resistance
- Insulation resistance
- Dielectric withstand
Mechanical Durability
- Mating cycles
- Pull force
- Vibration & shock
Environmental Validation
- Waterproof / pressure
- Temperature cycling
- Salt spray / corrosion
EMC / High-Speed
- Shielding effectiveness
- Signal integrity
- Insertion loss / crosstalk
Optical Verification
- Optical continuity
- Insertion loss
- Fiber channel verification
Custom Connector Engineering Capability Matrix
A quick overview of the main connector, electrical, mechanical, environmental and integration parameters that can be evaluated for application-specific custom connector projects.
| Customization Area | Typical Options | What We Need From You | Engineering Focus |
|---|---|---|---|
| Connector Structure Overall connector architecture |
Circular
Rectangular
Micro
Modular
Plug / Receptacle
Shell size, mating method, rear structure and special mechanical features can also be evaluated. |
Installation envelope, existing interface, mating requirements and equipment constraints. | Connector geometry, size, mating architecture, packaging space and compatibility with the target equipment. |
| Contacts & Inserts Electrical contact architecture |
Signal
Power
Mixed Size
Coaxial
Bus
Optical
Pin / socket arrangement, high-density layouts and mixed-function inserts. |
Contact count, current per contact, signal type, functional contacts and optical-channel requirements. | Contact size, spacing, density, insert layout, insulation geometry and mixed-function integration. |
| Mounting & Interface Equipment integration |
Panel Mount
PCB Mount
Bulkhead
Flange
Rack & Panel
Blind Mate
Straight PCB, right-angle PCB, surface mount and custom footprint review. |
Panel thickness, PCB location, available mounting space, panel opening and board geometry. | Mechanical fit, PCB footprint, alignment, panel interface, mating access and installation method. |
| Mating & Locking Connection and retention |
Threaded
Multi-Start
Bayonet
Push-Pull
Self-Locking
Blind-Mate
Multiple key positions and anti-mismating configurations can also be reviewed. |
Mating method, maintenance method, expected mating cycles and installation access. | Retention, anti-loosening, orientation control, anti-mismating and ease of maintenance. |
| Materials & Surface Finish Shell and protection materials |
Aluminum Alloy
Stainless Steel
Titanium Alloy
Aluminum Bronze
Copper Alloy
Passivation, nickel plating and project-specific corrosion-resistant treatment directions. |
Corrosion exposure, weight limitation, strength requirement, environment and qualification requirements. | Mechanical strength, corrosion resistance, electrical continuity, galvanic compatibility, weight and cost. |
| Environmental Protection Harsh-environment adaptation |
Waterproof
IP67 / IP68 Direction
Deep Sea
Wet-Mate
Salt Spray
Vibration
High temperature, shock, corrosion and special environmental requirements. |
Temperature, humidity, water exposure, water depth / pressure, vibration, shock, salt spray and chemical exposure. | Seal architecture, shell material, cable interface, locking, structural durability and qualification method. |
| Electrical & Data Transmission performance | Low-Level Signal High Current High Voltage Differential RF / Coaxial Data Bus | Working voltage, current per contact, signal type, data rate, impedance, RF frequency and cable / PCB details. | Contact selection, insulation geometry, spacing, impedance control, shielding and signal integrity. |
| Optical / Hybrid Mixed transmission architecture |
Single-Mode
Multimode
Fiber Contacts
Power + Optical
Signal + Optical
Optical and electrical channels can be combined where the connector architecture supports hybrid integration. |
Fiber type, optical channel count, electrical functions and mixed-transmission requirements. | Optical channel arrangement, insertion-loss verification, electrical separation and hybrid interface architecture. |
| Cable & Harness Integration Complete connector-to-cable solution |
Shielding
Strain Relief
Overmolding
90° Exit
Potting
Harness Integration
Rear accessories, cable clamps, heat shrink and protective conduit can also be integrated. |
Cable type, diameter, wire gauge, pinout, shielding requirement, cable exit and routing. | Cable-to-connector sealing, strain relief, shield termination, mechanical routing and ready-to-install assembly integration. |
| Testing & Validation Project-specific verification |
Electrical
Mechanical
Environmental
EMC
High-Speed
Optical
Testing is selected according to the approved project requirement. |
Required standards, customer-specific tests, acceptance criteria and qualification targets. | Verification plan, critical performance checks, prototype validation and qualification before production release. |
Engineering &Manufacturing
Engineering & Manufacturing
From precision component manufacturing and prototype assembly to validation and production implementation, engineering support can cover the complete custom connector development process.
Precision Manufacturing
Precision manufacturing can include CNC machining, stamping, contact production, molded insert manufacturing and shell production for application-specific connector designs.
Prototype Assembly
Prototype builds can integrate contacts, inserts, sealing components, cable termination and rear accessories for fit, function and engineering evaluation before pilot production.
Inspection & Validation
Validation can include critical dimensional inspection, electrical testing, mechanical checks, environmental testing and functional verification according to the project requirement.
Engineering Support
Engineering support can extend from application review and design assistance through optimization, DFM and tooling review, pilot-production support and final production implementation.
Frequently Asked Questions
Answers to common questions about custom connector modification, full-custom development, materials, electrical performance, environmental protection, testing and production support.
01 Can you customize an existing connector?
Yes. Where an existing product platform is suitable, modifications can include contact arrangement, keying, shell finish, mounting, termination, rear accessories and cable integration.
02 Can you develop a connector from drawings or a sample?
Drawings, samples, interface dimensions and performance requirements can be used as engineering input. Final design feasibility must be evaluated before the project is accepted.
03 Can you replace an obsolete connector?
Yes. Replacement projects can be evaluated. We will review the mating interface, dimensions, electrical requirements, environment and compatibility target before recommending an existing platform or custom development.
04 Can contact layouts be customized?
Yes. Contact count, contact size, pin / socket arrangement and mixed-function layouts can be customized within the mechanical and electrical limits of the connector architecture.
05 Can power and signal contacts be mixed?
Yes. Selected connector platforms support mixed-current and mixed-size contact arrangements. Fully custom layouts can also be evaluated.
06 Can coaxial, bus or fiber-optic contacts be integrated?
Yes. Selected modular and hybrid connector architectures support coaxial, twinax / bus, high-speed differential and optical contacts.
07 Can shell dimensions be customized?
Yes, in fully custom projects. For faster development, we may first evaluate whether an existing shell platform can be modified.
08 Can you customize the connector material?
Material options depend on product architecture and environment. The product portfolio includes aluminum alloy, stainless steel, titanium alloy, aluminum bronze and copper-alloy shell directions.
09 Can surface treatment be customized?
Yes, where compatible with the shell material and qualification requirement. Nickel plating, passivation and other corrosion-protection directions are available in the existing product portfolio.
10 Can you provide IP67 or IP68 connector solutions?
Yes. Existing waterproof product platforms include IP67 and IP68 directions. Final protection level depends on the complete connector, rear accessory, cable and assembly design.
11 Can you develop a deep-sea connector?
Yes. The existing product portfolio includes 1000 m+ deep-water and ultra-deep wet-mate connector technologies. A custom subsea project must define water depth, pressure, wet-mate requirement, cable, material and lifetime requirements.
12 Can you customize PCB mounting?
Yes. Straight PCB, right-angle PCB, surface-mount and application-specific board interfaces can be evaluated depending on the connector architecture.
13 Can you provide a complete cable assembly with a custom connector?
Yes. Connector development can be integrated with wire, cable, shielding, rear accessories, strain relief, overmolding, sealing and harness testing.
14 Can you provide prototypes?
Prototype support can be evaluated as part of the development process before pilot production and mass production.
15 What testing can you perform?
Depending on project requirements, testing can include contact resistance, insulation resistance, dielectric withstand, current, mechanical life, pull force, vibration, shock, temperature, salt spray, waterproof / pressure, EMI, high-speed signal and optical testing.
16 Can you support high-voltage or high-current custom connectors?
Yes. The existing product portfolio includes high-current and high-voltage connector platforms. Final contact size, insulation geometry, cable and thermal design must be engineered for the required load.
17 Can you support high-speed or RF custom connectors?
Yes. Coaxial, differential, bus and high-speed contact technologies are available in selected product families. Custom performance must be defined by frequency, data rate, impedance and cable / PCB architecture.
18 Can you develop hybrid optical-electrical connectors?
Yes. The portfolio includes optical-electrical hybrid technology, including wet-mate hybrid underwater connectors.
19 What information is required to start a custom connector project?
Please provide application, installation space, contact count, voltage, current, signal type, data rate / frequency, mounting method, cable details, environment, mating cycles, required standards and estimated quantity.
20 How do you decide between a modified standard product and a fully custom connector?
If an existing platform meets the basic interface and performance requirements, modifying a standard product usually reduces development time and risk. A fully custom connector is considered when the mechanical interface, electrical architecture or environmental requirement cannot be met by available platforms.
Who We Are
Your Partner for Industrial Connection Solutions
We specialize in industrial electrical connectors and related components, providing reliable connection solutions for demanding applications. Our products cover circular connectors, rectangular connectors, contacts, accessories, cable assemblies and customized solutions.
Engineering Excellence
Experienced engineers dedicated to solving complex connection challenges.
Customer Partnership
We listen, collaborate, and align our solutions with your goals and timelines.
Quality Commitment
Robust quality systems ensure reliability, traceability, and continual improvement.
Global & Responsive
Serving customers worldwide with agile support and reliable delivery.
Let's Build a Better Connection—Together.
Tell us about your application and our team will provide the right solution.