HIGH-DENSITY INTERCONNECTS IN SPACE-CONSTRAINED SYSTEMS
Optimizing Space Without Sacrificing Performance
In today’s advanced electronic systems, space is a luxury few engineers can afford. Whether designing for UAVs, portable medical devices, satellite modules, or next-generation avionics, compact form factors must still deliver uncompromising performance, durability, and reliability. High-density interconnect (HDI) solutions have become a critical component in making these compact, space-constrained systems viable.
At Meritec, our high-density interconnect solutions are engineered specifically for these demanding environments. With decades of experience and a deep understanding of harsh-environment requirements, we help innovators in aerospace, defense, medical, and industrial markets achieve compact, high-performance results without trade-offs.
What Are High-Density Interconnect Solutions?
High-density interconnects refer to cable and connector systems designed to support a large number of signals in a limited space. Unlike standard interconnects, HDI systems maximize signal count per square inch while minimizing crosstalk, signal degradation, and EMI susceptibility.
These solutions are especially relevant when:
- Size and weight must be reduced.
- Signal integrity is critical.
- EMI/RFI shielding is required.
- Systems must withstand environmental stressors like vibration, moisture, or thermal extremes.
Applications range from unmanned aerial systems (UAS), avionics panels, and implantable or portable medical devices to defense systems, robotics, and satellites.
Challenges in Space-Constrained Designs
Designing for compact systems presents unique engineering obstacles:
- Limited Real Estate: Components must be tightly packed without causing electrical interference or signal degradation.
- Thermal Management: Smaller assemblies may retain more heat, requiring careful material selection and routing.
- Mechanical Strain: Vibration, shock, and repeated use can compromise compact interconnects faster than standard-sized solutions.
- EMI/RFI Exposure: As components get closer, the risk of electromagnetic interference increases.
Meritec addresses each of these factors in our HDI cable assemblies and connectors by selecting advanced materials, applying custom shielding, and offering options like strain reliefs, potting, or overmolding to protect terminations.
Compact Interconnect Solutions by Meritec
Meritec’s engineering capabilities allow us to create interconnect systems with optimized signal density, durability, and long-term reliability in the most restricted form factors. Some of our key solutions include:
| Solution | Use Case |
|---|---|
| Hercules® High-Density Circular | Rugged environments needing multiple signal types (power, RF, fiber) |
| VHDM®/VITA Interfaces | Defense and aerospace systems requiring modular backplane interconnects |
| Custom Overmolded Assemblies | Medical and UAV designs where cleanliness, strain relief, or waterproofing is key |
| Flex Circuit + Cable Hybrids | Tight routing in control panels or sensor-driven systems |
| MIL-Qualified Micro Connectors | Compact mil/aero applications with stringent reliability standards |
Each solution is available in standard or custom configurations, with fast prototyping and low-volume flexibility.
Case Example: UAV Payload Integration
In a recent project for a defense UAV manufacturer, Meritec was tasked with redesigning a legacy harness system that suffered frequent failures due to vibration and poor shielding. The new design required:
- Minimal weight increase
- High EMI protection
- Integration of signal, power, and control lines
Our engineering team created a hybrid flex + micro coax HDI solution with overmolding and strain relief. The result? A 40% reduction in assembly size, 60% longer service life, and a full pass on MIL-STD-810 vibration testing.
Meeting Industry Standards
All Meritec high-density interconnect solutions are tested against industry benchmarks to ensure performance in real-world environments. We support or exceed standards including:
- MIL-STD-810 (Environmental Engineering)
- DO-160 (Avionics Equipment Environmental Conditions)
- ISO 10993 (Biocompatibility for Medical Devices)
- IP67/IP68 (Ingress Protection Ratings)
- Custom Lab and Field Testing per customer application
Our in-house test lab and design team work together to validate assemblies in conditions mirroring your actual use case.
Industries We Serve
Meritec's HDI systems are designed for use across high-impact industries:
- Aerospace & Avionics: Flight-critical systems, navigation, satellite modules
- Defense & Military: Tactical radios, UAVs, soldier-wearable tech
- Medical: Diagnostic imaging, portable monitors, implantable devices Industrial
- Automation: Compact robotics, inspection systems
- Marine & Subsea: Pressure-rated and corrosion-resistant interconnects
Each product line is supported by deep engineering knowledge, fast turnaround prototyping, and low- to mid-volume production tailored to customer needs.
Build Your System with Meritec
Space-constrained designs don’t leave room for compromise. Meritec delivers compact interconnect systems that meet rigorous standards across aviation, medical, and defense applications. Whether you're dealing with a UAV payload or a handheld diagnostic device, we have the design, materials, and testing capabilities to deliver HDI assemblies that work.
Build Your Subsea Solution with Meritec
Subsea systems require more than rugged parts they demand complete, integrated solutions engineered for the application. Meritec brings decades of experience in harsh-environment interconnects to help your marine system succeed. If you need assemblies that stand up to the challenges of the deep, talk to our team today.
Build Your Interconnect System with Meritec
Miniature systems need maximum performance. Meritec specializes in high-density, high-reliability cable and connector assemblies designed for compact environments. Whether you're designing for a drone, avionics control panel, or portable medical unit, our team is ready to help you optimize your design.
Start Your Next HDI Project with Meritec
Ready to build a compact system that delivers performance under pressure? Meritec’s high-density interconnect solutions are engineered to meet the demands of today's most advanced applications. From concept to custom production, our team is here to support your success.
Explore Meritec high-density capabilities:
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