XACT engineered a 100% shielded, field-repairable fuse holder for the U.S. Army’s M1 Abrams main battle tank. The redesigned assembly improved EMI protection, reduced field downtime, and enhanced mission readiness in harsh armored vehicle environments.
Program Overview
XACT Engineered Manufacturing Solutions was engaged to resolve a field reliability issue affecting electrical subsystems on the M1 Abrams main battle tank platform operated by the United States Army.
The challenge required a defense-grade redesign aligned with our Military-Grade Cable Assemblies capabilities, built for extreme vibration, shock, and electromagnetic interference conditions typical of armored vehicle platforms.
The Challenge
The U.S. Army was experiencing recurring performance issues with a field-repairable fuse holder used within the Abrams electrical architecture.
Key technical concerns included:
- Insufficient EMI shielding
- Exposure to high vibration and mechanical shock
- Environmental durability limitations
- Increased field service time
- Reduced platform readiness
Electrical reliability in armored ground vehicles directly impacts operational availability. The fuse holder required redesign to improve shielding performance, durability, and field serviceability.
The Engineering Solution
Through a structured evaluation using our Engineering Design Services, XACT developed a redesigned, fully shielded, field-repairable fuse holder assembly optimized for military vehicle deployment.
The upgraded assembly incorporated:
- 100% EMI shielding architecture
- Ruggedized mechanical structure for vibration resistance
- Field-repairable configuration to reduce downtime
- IPC/WHMA-A-620 Class 3 workmanship standards
- Full traceability and documentation support
Where additional electromagnetic mitigation strategies were required at the enclosure level, shielding continuity was supported through engineered material solutions such as Shielded Gasket Solutions, the EMI Shielding portfolio, EMI Foil Tape Solutions, and RF Absorbing Solutions.
This system-level integration ensures shielding effectiveness across both interconnect and enclosure interfaces.
Results
Following validation and evaluation, the United States Army approved and adopted the redesigned shielded fuse holder for integration into M1 Abrams platforms.
Program impact included:
- Reduced field service downtime
- Improved electrical reliability under combat vibration profiles
- Increased mission readiness
- Long-term deployment adoption
The solution remains in service today and reflects XACT’s capability to deliver ruggedized interconnect systems for mission-critical defense programs.
Defense Manufacturing Capabilities
This program reflects XACT’s broader expertise across:
- Military-Grade Cable Assemblies
- Overmolded Cable Assemblies
- Rugged & Harsh Environment Assembly Solutions
- Custom Cable Assemblies
- Cable Repair & Recertification
Supporting production continuity through structured Supply Chain Management, integrated Value-Added Services, and precision Machining & Fabrication.
Compliance & Certifications
XACT supports controlled defense programs under AS9100D / ISO 9001 certification and IPC Class 3 workmanship standards.
Full compliance documentation is available on our Certificates & Accreditations page.
Our supply chain transparency policies can also be reviewed through our Conflict Minerals Statement.
Integrated Materials & Interconnect Strategy
Complex defense systems often require coordinated material and interconnect engineering.
Through our Integrated Interconnect & Cable Assembly Solutions approach, Matrix provides engineered EMI, thermal, sealing, and identification materials while XACT manufactures ruggedized cable assemblies, overmolds, connectors, and electromechanical builds.
This integrated structure reduces program risk and improves shielding, sealing, and overall system reliability.
Supporting Long-Life Defense Programs
Defense platforms demand long lifecycle support and production continuity. XACT provides:
- Controlled documentation management
- Secure engineering collaboration
- Repair and refurbishment of fielded assets
- Recertification for defense and regulated programs
For secure drawing submission or engineering consultation, visit our Contact page or explore our full Military-Grade Cable Assemblies capabilities.
