Smaller, smarter, greener connectors

The trend toward miniaturisation has firmly taken hold in the electronics industry. As devices become smaller and lighter, the components inside them must follow suit — without sacrificing performance, durability or reliability. From automotive electrification to advanced medical devices, demand for compact, lightweight connectors is reshaping design priorities across multiple sectors.

According to Mark Baptista, Global Strategic Accounts Sales Engineer at PEI-Genesis, the challenge lies in balancing reduced size with high electrical performance and long-term reliability.

Designing for tighter spaces
Modern electronics must deliver more power and functionality within increasingly confined spaces. In smartphones and wearables, connectors must fit into compact housings while maintaining signal integrity. In medical environments, components must withstand repeated sterilisation cycles at temperatures up to 250°C, along with aggressive chemical cleaning processes.

In the automotive sector, electrification and advanced driver-assistance systems require lightweight connectors capable of supporting high-current systems, often up to 1000V. Integrating multiple power sources into a single connector design helps reduce overall system weight without compromising performance — a critical factor in improving vehicle efficiency and range.

Materials innovation at the core
Miniaturisation begins with materials. Traditional connector materials are being replaced or enhanced to meet stricter performance and sustainability demands.

Composite materials and advanced polymers are increasingly used for connector housings and insulation. These materials combine low weight with high mechanical strength and improved resistance to electromagnetic interference (EMI), ensuring reliable performance in compact applications.

Nano-coatings — often no thicker than 2 micrometres — add protective layers that enhance corrosion resistance, conductivity and mechanical durability. By improving lifespan and performance, these coatings enable smaller connectors that remain robust in demanding environments.

Miniaturisation meets sustainability
The shift toward smaller connectors has also created opportunities to improve environmental performance. Manufacturers are responding to regulatory pressure and sustainability goals by adopting Restriction of Hazardous Substances (RoHS)-compliant materials, eliminating hazardous elements such as lead, mercury and cadmium.

Alternative materials, including silver, nickel and Tin-Silver-Copper solder alloys, reduce toxicity while maintaining electrical performance. Meanwhile, advanced manufacturing techniques such as 3D printing and precision injection moulding help minimise material waste compared to traditional machining processes.

Industry leaders are also investing in cleaner production. For example, Amphenol reported a 34% reduction in revenue-normalised Scope 1 and 2 greenhouse gas emissions in 2024 compared to 2021. High-demand solutions such as Amphenol’s 2M Series micro-miniature connectors — supplied by PEI-Genesis — align with this broader push toward more energy-efficient and environmentally responsible production.

A compact future with lasting impact
Miniature connectors demonstrate how innovation in design, materials science and manufacturing can deliver both performance gains and sustainability improvements. As industries continue to demand lighter, smarter and greener electronics, collaboration across engineering disciplines will be essential.

By rethinking connector design at every level — from materials to manufacturing — the electronics sector is proving that smaller components can make a significant impact on both performance and environmental responsibility.

www.peigenesis.com