This document discusses how canted coil springs can help overcome size, weight, and power (SWaP) challenges in electrical connectors. Canted coil springs can serve multiple functions by providing latching, conducting electricity, and electromagnetic interference/radio frequency interference (EMI/RFI) shielding in a single compact component. They conduct high currents efficiently in a small space without overheating. Springs are customizable for unique applications and can be made from various conductive materials to meet requirements. The document provides examples of how canted coil springs are used in connectors for commercial aviation, military aviation, and recommends early collaboration with spring engineers to design connector components that meet all system needs.

1. Overcoming SWaP Challenges With Canted
Coil Springs
James Mecredy, Global Market Manager
Bal Seal Engineering, Inc.

2. Slide 2
Topics
• Modern Electrical Connectors
• Connector Engineering Challenges
• Canted Coil Spring Solution
• Addressing SWaP Requirements
• Spring Sizes, Characteristics, Materials
• Commercial & Military Applications
• UAV Connectors: A Deeper Dive
• Summary & Recommendations

3. Slide 3
Electrical Connector Attributes
• Consists of male/female jack and plug design
• Joins electrical terminations, ensuring
continuous flow of current & signal
• Often employs separate mechanical latching &
EMI/RFI shielding components, increasing
size/weight
• Demands repeatable, consistent performance

4. Slide 4
Connector Engineering Challenges
• Reduce size, weight and power consumption (SWaP)
• Fulfill multiple mechanical and electrical functions
 Latching
 Conducting
 EMI/RFI Shielding
• Manage high current in small form without
temperature spike
• Resist shock and vibration
• Consistently perform over 1000s of cycles

5. Slide 5
Canted Coil Springs Can Help:
• Reduce Size & Weight
 Latching + Conducting + EMI/RFI
Shielding in one component means
fewer parts & simpler designs
• Conduct More Power
 Canted coil springs achieve higher
power density through design &
material science
• Extend Product Life
 Springs are resistant to compression
for 1000s of cycles
• Highly customizable to meet
unique land, sea, and air
service requirements

6. Slide 6
Mechanical Latch
The canted coil spring can be used for sliding, latching,
or permanent connections

7. Slide 7
Electrical Contact
The canted coil spring offers
• High power density
• Cooler operation
• Compact footprint
• Individual coils ensure consistent
current/signal flow in environments
with vibration, surface irregularities
and misalignment
• Simplified installation &
maintenance

8. Slide 8
EMI/RFI Shield
Canted coil spring geometry and electrical properties
make it ideal for use as EMI/RFI shielding component
Results for a Ø.657” silver-plated BeCu spring with compressed height of ~.0625”

9. Slide 9
Spring Sizes & Configurations
 Can only be deflected along coil
height – NOT coil width
 Wire diameter from .002” to .065”,
coil height from .025” to .700”
 Cut-length, axial and radial
orientation
 Customized loads from a few ounces
to 100s of pounds
Radial Spring
Coil Width
Coil
Height
Wire
Diameter
Axial Spring

10. Slide 10
Wire Materials
Canted coil spring wire materials can be selected to meet
specific application requirements, including corrosion
resistance, conductivity, more
 Stainless steel 300 series
 MP35N®
 Platinum iridium
 Titanium
 Hastelloy®
 Inconel®
 Beryllium-copper alloy
 Zirconium-copper alloy
 Gold, silver, nickel, and tin plating

11. Slide 11
Optimizing Aerospace Electrical Connector
Spring Design
Requirements* Solutions
• High current-carrying
capacity
• Low contact resistance
• Bal Spring® material selection (dependent on
hardware materials)
• Copper alloys (ZCC, K88, BEC)
• Silver plating for greater conductivity OR gold
plating for harsh, corrosive environments
• Groove configuration
• V-bottom groove
• Mechanical connecting
(latching)
• Optimize groove and Bal Spring® canted coil spring
configuration to meet latching (force) requirements
• V-bottom or flat bottom groove
• Bal Spring radial spring
• Material selection dependent on specific force
and/or conductivity requirements
• EMI/RFI Shielding • Base materials: copper alloys and stainless steel
alloys
• Silver plating for greater conductivity
• Galvanic compatibility
• Bal Spring® canted coil spring’s force over large
compression range provides consistent shielding
despite surface irregularities and tolerance variations
Bal Spring® latching
spring detail
*NOTE: Spring design characteristics can be optimized to meet more than one requirement.

12. Applications – Commercial Aviation
IN-FLIGHT ENTERTAINMENT
SYSTEMS (IFE) CONNECTORS
ELECTRICAL SUBSYSTEM
CONNECTORS
COMMUNICATIONS
EQUIPMENT CONNECTORS
Springs in Electrical Connectors for Commercial Aviation

13. Applications – Military Aviation
FUTURE SOLDIER
EQUIPMENT CONNECTORS
AIRCRAFT SYSTEMS
CONNECTORS
POWER MANAGEMENT &
BACKUP CONNECTORS
OPTOELECTRONICS
CONNECTORS
Springs in Electrical Connectors for Defense

14. Slide 14
Summary & Recommendations
• To eliminate costly mistakes and
delays, consider connector
component requirements as part
of overall design
• In early design stages, collaborate
with a spring engineering partner
like Bal Seal Engineering to:
 Custom-design connecting, conducting
and EMI shielding components to meet
all your system/application
requirements
 Produce high-quality prototypes
 Perform testing to verify performance
 Force
 Conductivity
 Shielding effectiveness
 Transition successful prototype to full
production; 100 to 1M+ units

15. Slide 15
Resources & Contact Information
James Mecredy
Global Market Manager, Aerospace & Defense
Bal Seal Engineering, Inc.
marketing@balseal.com www.balseal.com +1 949.460.2322 Design Request Form

16. Custom components that drive
tomorrow’s technologies®
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