Next-Gen Connectors Push Boundaries in EVs, Medtech, and Aerospace

As electrification, automation, and precision medicine reshape global industries, one type of component is quietly enabling their progress: connectors. These small but critical parts are evolving rapidly to meet the unique challenges introduced by rising voltages, shrinking spaces, and increasingly complex device architectures. Whether inside an EV battery pack, a surgical catheter, or an aerospace power module, next-generation connectors are a crucial precursor to overall performance and reliability.

From high-voltage automotive systems to sterilization-proof medical devices and EMI-sensitive military electronics, modern connectors must do more than just link components. They must deliver exceptional durability, signal integrity, and compliance with demanding global standards. The latest connector launches from JAE, Phillips Medisize, and Harwin show how manufacturers are responding with compact, customizable solutions that meet today’s toughest design and regulatory needs across sectors.

JAE MY05 Series: Compact Connectors for High-Voltage EVs

JAE’s newly released MY05 Series targets the next generation of electric vehicles, where battery voltages are rising to 800 V and beyond, enabling faster charging. The MY05 is rated for 1,000-V operation and 4,800-V dielectric strength, meeting insulation and creepage distance requirements as specified in IEC 60664-1. These compact, low-current connectors meet automotive-grade standards, including USCAR-2/37 and LV214/215.

JAE’s new MY05 Series connector was developed for high-voltage, low-current connections that conform to the IEC 60664 standard. Image used courtesy of JAE

The series is designed for battery control units (BCUs) and battery management systems (BMSs), with configurations supporting both European-standard and JAE MX80 terminals. Available in 10- and 14-pin formats, with options for connector position assurance (CPA), these connectors also support flexible system design through straight and right-angle header variations. With superior insulation integrity and miniaturization, MY05 closes a long-standing market gap for robust high-voltage automotive connectors.

Phillips Medisize TheraVolt: Customizable Medical Connectors

Phillips Medisize, a Molex company, has launched its TheraVolt medical connectors to address the growing complexity of modern therapeutic devices. Supporting up to 220 contacts and high-voltage applications, TheraVolt is purpose-built for electrophysiology tools, endoscopes, and cardiovascular diagnostic systems. These circular connectors can handle multiple therapy options, signal transmission, and robust data collection, all within compact, sterilization-resistant housings.

The TherVolt connectors inttegrate more functionalities than standard connectors, with pin counts ranging from 68 to 220 contacts per connector. Image used courtesy of Molex

Phillips engineered the TheraVolt connectors for extreme reliability, featuring hyperboloid contacts that can withstand up to 30,000 mating cycles. They withstand repeated autoclave sterilization, support voltages up to 2.2 kV, and can be tailored to customer-specific pin counts and electrical profiles. Their cross-platform compatibility helps reduce customization cycles and simplifies integration, improving both time to market and long-term system durability.

Harwin Kona Connectors: Space-Saving Power Delivery for Harsh Environments

 Harwin has expanded its high-current Kona Series with new right-angled, single-in-line (SIL) power connectors, tailored for aerospace, military, and embedded systems. These connectors deliver 60 A per contact and feature EMI shielding for improved signal integrity in noise-sensitive environments. The new lineup includes angled cable and through-board configurations, designed for high-density layouts where board space is limited.

The Kona right-angle, single-in-line power connectors will feature nine two, three, and four-pin connectors for through-board or board-to-panel configurations. Image used courtesy of Harwin

Constructed with beryllium copper contacts and gold plating, Kona connectors ensure long-term electrical performance. The design features recessed contacts, polarized mating, and rugged PPS thermoplastic housings rated for temperatures ranging from -65°C to +150°C. EMI shielding accessories help meet stringent compliance requirements. The right-angled form factor expands Harwin’s reach into space-constrained control systems for UAVs, ground vehicles, and other mission-critical platforms.

As industries advance, even components as simple as connectors can play a significant role in a product's success. From high-voltage EV systems and sterile to ruggedized aerospace applications, the connector landscape is evolving rapidly. Products like JAE’s MY05, Phillips Medisize’s TheraVolt, and Harwin’s expanded Kona line prove that connectivity is no longer just about making contact, but about delivering power and reliability.