Military-Grade Cable Assemblies — with EMI/Thermal Materials Support

AS9100 / IPC Class 3 builds with full traceability and test data on every assembly.

Built for soldier-worn comms, vehicle comms, rugged C2 systems, expeditionary power, unmanned platforms, sensors, and masts. Engineered for durability, compliance, and performance in harsh military environments.

What We Deliver

MIL-Spec Wire Harnesses &
Box Builds

sealed, shielded, and overmolded; documented travelers with lot-level traceability.

Rugged Overmolds &
Strain Relief

IP67/68-style terminations validated for shock, vibration, and fluids.

DAGR Accessories &
Military Interfaces

field-proven connectors, adapters, and cables for soldier-borne navigation and comms systems.

Validation & Compliance

continuity, insulation resistance, Hi-Pot, RF/VSWR, mechanical, and environmental testing (thermal cycling, salt fog, moisture ingress).

Repair & Recert Programs

depot/MRO short runs and backlog-buster batches for fielded kits.

Mission Applications

A soldier wearing a helmet and headset looks through equipment inside a military vehicle, surrounded by essential Military Cable Assemblies.

Soldier-Worn Communications

Low-profile magnetic or push-pull connectors, Micro/Mini-38999, headset/audio, DAGR, and radio accessories. Lightweight looms with 360° shield terminations.

A soldier in uniform sits in the driver's seat of a military vehicle, with electronic equipment, military cable assemblies, and a monitor installed in the front passenger area.

Vehicle Communications & Power

Heavy-gauge DC harnesses, ECU I/O looms, sealed backshells, LSZH options. Validated for vibration, salt fog, and temperature cycling.

A tan mobile command center with open rear doors reveals multiple computer monitors, military cables, and chairs, situated on grass with trees in the background.

Rugged C2 Systems & Shelters

Panel/bulkhead cabling, RF/data trunks, and feed-throughs with EMI/environmental sealing for racks, containers, and command posts.

Soldier-Worn Communications

Low-profile magnetic or push-pull connectors, Micro/Mini-38999, headset/audio, DAGR, and radio accessories. Lightweight looms with 360° shield terminations.

A close-up of a tactical vest with military cables and communication equipment attached, showing dust and dirt on the surface.

Expeditionary Power

High-current, abrasion-resistant assemblies with molded strain relief. Moisture-ingress tested and documented.

A military surveillance or communications trailer equipped with an extended antenna mast and robust military cable assemblies is positioned in a grassy field surrounded by trees under a partly cloudy sky.

Unmanned Platforms, Sensors & Masts

Lightweight, sealed RF/power harnesses. Encapsulated and overmolded protection for harsh environments.

Why Programs Choose XACT

Logo with the word "MATRIX" in black and "XACT" in red, accompanied by the tagline "Engineered Manufacturing Solutions"—your trusted partner for Military cables and advanced military assemblies.

Matrix Materials Integration

Enhance your electronics with engineered EMI and thermal materials from Matrix Technology Ltd., a trusted partner to XACT Engineered Manufacturing Solutions.

Ideal for defense and aerospace — vehicles, shelters, UAVs, and comms hardware.

Get Started

Ready to integrate rugged, military-grade cabling and materials into your next defense program? Use the contact form below to share your drawing set, pin-map, or environmental spec — or request a sample kit to begin evaluation.

Frequently Ask Questions

XACT Engineered Manufacturing Solutions is qualified to support controlled defense and aerospace programs through AS9100D / ISO 9001 certification and compliance with IPC Class 3 workmanship standards.

 

We maintain Controlled Goods Program (CGP), Joint Certification Program (JCP), and ITAR registrations, along with CMMC Level 2 readiness.

 

Once NDAs and export-control reviews are in place, we can manufacture and test assemblies for a wide range of ground, airborne, and expeditionary defense systems.

XACT integrates connector families from the world’s most trusted defense manufacturers:

 

  • Amphenol — 2M Micro38999, MIL-DTL-38999 Series III, MIL-DTL-55116 Audio (164 Series), Stingray, Terrapin/SCE2, Warrior Grip
  • TE Connectivity — D38999, 369 Series
  • ITT Cannon — MKJ Warrior, Nemesis, Nemesis II
  • Additional ecosystems: RF (SMPM/VITA-67), filtered or hermetic circulars, backshells, and environmental sealing hardware

 

All connectors are assembled to IPC/WHMA-A-620 standards and verified for mechanical integrity and shielding performance.

Each assembly is delivered with full electrical, mechanical, and environmental validation documentation, including:

 

  • Continuity and insulation resistance
  • Dielectric withstand (Hi-Pot) and RF/VSWR where applicable
  • Pull strength, flex, and overmold adhesion testing
  • Environmental testing: thermal cycling, salt fog, moisture ingress, submersion
  • First Article Inspection (FAI) and lot-level traceability

 

Testing can be performed to customer-specified standards or MIL-STD validation requirements.

XACT specializes in engineered interconnect and harness solutions across defense platforms, including:

 

  • Overmolded and sealed MIL-spec harnesses
  • Micro/Mini-38999 cable sets
  • DAGR / tactical radio leads and accessories
  • Headset / audio cables (M55116)
  • RF / coax / triax / twinax jumpers
  • Vehicle DC power looms and ECU I/O harnesses
  • Panel / bulkhead interconnects
  • Mast and sensor harnesses
  • UAV payload and ground station cabling
  • Expeditionary power leads
  • Repair / recertification kits for fielded equipment

 

Each build is traceable, environmentally tested, and compliant with AS9100 / IPC Class 3 workmanship standards.

Yes. XACT routinely operates under CGP, ITAR, and JCP compliance.

We can sign mutual NDAs and securely manage export-controlled data.

 

Customers may submit drawings, pin maps, and specifications via encrypted transfer; a countersigned NDA is returned before DFM review begins.

Still have questions?