Connector Comparison Matrix

A worked version of the matrix from Exercise 2, filled with representative figures from the manufacturer datasheets and standards cited in each cell. To score your own application, copy the table and blank the cells.

Read the numbers as orientation, not specification

Every figure below is a typical or example value for the family, pulled from the source footnoted in the cell — not a rating for any exact part. Current in particular depends on the specific contact, wire gauge, number of loaded contacts, temperature, and derating curve (see Selection Workflow §2). Verify against the current datasheet, the applicable standard, and the QPL before relying on any value in released hardware. When this table and a datasheet disagree, the datasheet wins. A catalog rating is not a permission slip: use these figures as a screening tool, and the exact datasheet, derating curve, application specification, and program/customer requirement for design release.

Family	Environment	Pin count	Current (per contact)	Sealing	Tooling	Cost	Lead time	Serviceability	Common mistakes	Notes
MIL-DTL-38999 Series III	Harsh aero/defense; wide temp range	Shells 9–25; ~2 to 100+ contacts1	Size-dependent; e.g. size 16 ≈ 10 A, size 12 ≈ 17 A (example test currents)2	IP67 mated1	AS39029 crimp; positioner + insert/extract tools	High	Often long	Rear-release removable crimp; ~500 cycles1	Wrong crimp tool; omitted backshell; keying/gender errors	Threaded Tri-Start, scoop-proof; hybrid inserts (coax/twinax/power)
MIL-DTL-26482 (Series 2)	Rugged mil/industrial; bayonet	Multiple shells; contact sizes 20/16/123	Size-dependent (20/16/12) — verify per catalog3	Environmental when mated; IP-rated variants	M39029 crimp + insert/extract tools	Med–High	Moderate–long	Removable crimp; ≥ 500 cycles3	Assuming bayonet suits every vibration profile; wrong contacts	Fast 3-point bayonet; 600 V (Class I) / 1000 V (Class II)3
M12 A-coded	Industrial sensors, actuators, I/O	3/4/5/8-pin (2–17 way)4	≤ 4 A4	IP67 mated; IP68/IP69K variants5	Molded cordsets or field-wireable	Low–Med	Short (COTS)	Field-wireable variants; screw-lock	Assuming all 4-pin pinouts are alike; IP applies while unmated	IEC 61076-2-101; ≤ 250 V, ≤ 100 MHz4
M12 X-coded	Industrial Ethernet	8-pin5	Signal/data level — verify per datasheet	IP67 mated5	Molded cordsets or field-wireable	Med	Short–Med	Field-wireable variants	Unshielded cable on X-coded; using D-coded for GbE	IEC 61076-2-109; up to 10 Gbit/s, Cat 6A (≤ 500 MHz)5
D-sub (MIL-DTL-24308)	Non-environmental; racks, panels, test gear6	9/15/25/37/50; up to 104 (size 22D)6	Size 20 & 22D contacts; low-current signal/control — verify6	Non-environmental (standard); ruggedized variants exist6	M39029 crimp or solder cup; insert/extract tools6	Low–Med	Short	Removable-crimp variants; 500 cycles6	Assuming "mil-spec" = sealed; jackscrews left loose	Polarized shell, rack & panel; −55 to +125 °C6
Micro-D (MIL-DTL-83513)	Compact high-reliability; internal / protected	9 to 100 (standard layouts)7	3.0 A8	Not sealed on its own (interfacial-seal option); treat as internal	twist-pin (or stamped-and-formed) crimp, or PCB/solder; assembly-intensive	High	Moderate–long	500 cycles; delicate8	Using it for high current or dirty field service; handling damage	600 V rms SL / 150 V at 70k ft; .050 in (1.27 mm) centers8
Industrial rectangular / Han-style	Machinery, panels, removable modules	Modular inserts; Han E 6–48 contacts/insert9	16 A (Han E); higher-current inserts available (e.g. Han HC)9	Hood-dependent (IP65–IP69K options)	Crimp or screw/cage-clamp; insert tooling	Med–High	Moderate	Modular, serviceable inserts; 500 cycles (Han HMC higher)9	Wrong insert/hood combination; sealing assumed without a rated hood	500 V (Han E); mixed power/signal/data in one housing9
Molex Micro-Fit 3.0	Internal, non-sealed; −40 to +105 °C10	2–24 circuits10	≤ 8.5 A, terminal-dependent (a 10.0 A RMF terminal is offered — verify exact terminal P/N)10	Non-sealed10	Crimp terminals; hand or applicator tooling	Low	Short (COTS)	Crimp; ~30 cycles (250 with lubricated RMF)10	Exceeding the rating; no TPA/keying in volume production	3.00 mm pitch; 600 V; positive latch, TPA, polarization10

Contact sizes, insert arrangements, and exact ratings vary by manufacturer and part number — always pull the specific datasheet and, where qualification matters, the QPL.

When you reuse this matrix for your own trade study, add evidence columns so it stays reviewable: Rating source (document + rev/date), Requirement type (customer / standard / manufacturer / internal / assumption), Verification status (verified / assumed / example / TBD), and Derating curve checked (yes / no / n-a). The rows above are example-only family orientation, sourced per the footnotes — not release values.

Sources

Footnotes

1. Amphenol Aerospace, MIL-DTL-38999 Series III — environmentally sealed (IP67 when mated), durability commonly evaluated at 500 mating cycles, shell sizes 9–25, AS39029 removable crimp contacts (sizes 22D/20/16/12/8). https://amphenol-aerospace.com/products/mil-dtl-38999-series-iii-tv ↩ ↩² ↩³

2. Contact current is size-dependent. Figures such as size 16 ≈ 10 A and size 12 ≈ 17 A are AS39029 example test currents / relative sizing aids, not guaranteed continuous ratings — size against the specific contact datasheet and derating curve. See the MIL-DTL-38999 Deep Dive. ↩

3. MIL-DTL-26482 Series 2 catalog (Aero-Electric / Amphenol) — quick-disconnect 3-point bayonet, ≥ 500 mating cycles, 600 V (Service Class I) / 1000 V (Service Class II), crimp contacts in sizes 20/16/12. https://www.aero-electric.com/PDF/MIL-DTL-26482%20Series%202.pdf ↩ ↩² ↩³ ↩⁴

4. IEC 61076-2-101 (M12 circular connectors with screw-locking, A/B/D coding) — 2- to 17-way; data transmission up to 100 MHz; signal and power up to 250 V and up to 4 A per contact. https://webstore.iec.ch/en/publication/77773 ↩ ↩² ↩³

5. IEC 61076-2-109 (M12 X- and H-coding, data up to 500 MHz) and manufacturer datasheet — 8-way X-coded, up to 10 Gbit/s, Cat 6A, IP67 when mated. https://media.metz-connect.com/files/171/Data_sheet_MNF881A315-0001.PDF ↩ ↩² ↩³ ↩⁴

6. MIL-DTL-24308G (DLA detail specification) — nonenvironmental, polarized-shell, rack-and-panel; −55 to +125 °C; 500 mating/unmating cycles (§4.5.18); contact sizes 20 (standard density) and 22D (high density); positions 9/15/25/37/50, up to 104 for size 22D. https://mm.digikey.com/Volume0/opasdata/d220001/medias/docus/7139/5831_mil-dtl-24308.pdf ↩ ↩² ↩³ ↩⁴ ↩⁵ ↩⁶ ↩⁷

7. Micro-D standard shell layouts (9, 15, 21, 25, 31, 37, 51, 100 contacts) — ConnectorSupplier / Bishop & Associates, "What are MIL-DTL-83513 connectors?" https://connectorsupplier.com/what-are-mil-dtl-83513-connectors/ ↩

8. Glenair, Micro-D Performance Specifications (MIL-DTL-83513) — 3.0 A continuous per contact from −55 to +150 °C, 600 V rms at sea level / 150 V at 70,000 ft, 500 mating cycles, .050 in (1.27 mm) contact centers. https://www.glenair.com/micro-d/pdf/micro-d-specifications.pdf ↩ ↩² ↩³

9. HARTING's own product page for the Han E 16-pole insert (09330162601) states 16 A, 500 V, 500 mating cycles. https://www.harting.com/en-US/p/Han-E-16-Pos-M-Insert-Screw-09330162601 The 6–48 contacts-per-insert span is a family-range figure from distributor listings — verify the HARTING catalog for your exact insert (TME family listing: https://www.tme.com/us/en-us/details/09330162601/harting-connectors/harting/). The Han family also offers higher-current inserts (e.g. Han HC) and high-mating-cycle variants (Han HMC). ↩ ↩² ↩³ ↩⁴

10. Molex, Micro-Fit 3.0 Connector System Product Family (document 987650-5984, Rev. 5) — states an "8.5A maximum current rating," with current "determined by terminal used" (600 V, 3.00 mm pitch, 2–24 circuits, −40 to +105 °C, non-sealed; durability typically 30 cycles, up to 250 with factory-applied lubricant on RMF terminals). The same document offers a "10.0A RMF terminal"; its ordering table lists RMF terminals in 20–30 AWG (series 46235) and 18 AWG (series 203951). RMF primarily means Reduced Mating Force — current is set by the exact terminal P/N and wire gauge, not by the RMF designation itself. https://www.content.molex.com/dxdam/literature/987650-5984.pdf ↩ ↩² ↩³ ↩⁴ ↩⁵ ↩⁶