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

In response to growing demand from the defense sector, franchised connector-assembly specialist PEI-Genesis has significantly expanded the MIL-DTL-38999 production capability at its 65,000 ft² European assembly facility in Southampton. The company is QPL listed by the US Department of Defense for assembling the MIL-DTL-38999 Series I, II and III military circular connectors manufactured by Amphenol. PEI-Genesis also assembles Amphenol MIL-DTL-38999 connectors at its 150,000 ft²South Bend Indiana USA facility.

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 an operations manager at the Southampton facility. “This involves very close collaboration between the two organizations 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 customized 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.

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.