Backshell Considerations for Mission-Critical Mil/Aero

Applications
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Contributed Article January 19, 2018

Affording backshells the same design process considerations

as connector selection can help prevent delays, cost overruns,
and premature failures in mission-critical mil/aero applications
Rudy Ramos, Project Manager – Technical Content Marketing, Mouser Electronics

Mil/Aero connectors are designed for a variety of mission-critical, harsh-environment

applications, including commercial and military avionics, satellites, and weapons systems.
Connector selection is often given much consideration in these applications, but such care is
not always afforded to the backshell portion of a connector, which, within the world of circular
Mil-Spec connectors, is generally interchangeable with “cable clamp,” “strain relief,” or simply
“clamp.” By ignoring this essential part of a connector, engineers can open projects up to
potential delays, cost overruns or — even worse — premature connector failure.

Figure 1: Backshells help ensure

high-performance connections and
long-lifetime performance in
mission-critical mil/aero
applications like NASA’s Curiosity
Mars Rover

Although some Mil-Spec connectors

include a backshell (e.g.,
Amphenol’s MS3116F and
MS3106F Series), the vast majority
of them require a separate order for
the backshell. The issue is not whether all Mil-Spec circular connectors come with backshells,
though. The issue is that, all too often, the connectors get all of the design process attention
and the backshells become an afterthought.

Connector Backshells
A backshell is the back portion of a connector. It is typically a separate piece that screws or
locks onto the connector shell, and most suppliers considered it a connector accessory.

Connector backshells are specifically designed to protect the back portion of a connector shell
(plug or receptacle) that houses the contacts to which wires or cable are either crimped or
soldered. Backshells may include a cable clamping mechanism (Figure 1) that provides strain
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relief to the cable or wires to prevent mechanical stress from reaching a connector’s soldered
or crimped terminals. Such strain relief ensures a high-performance connection and long-
lifetime performance, both of which are essential requirements in mission-critical applications.
Connector backshells can also provide sealing protection against harsh environments,
electromagnetic interference (EMI), and radio frequency interference (RFI), and can serve as a
grounding point for the cable shield drain wire.

Figure 2: In this diagram of a backshell, self-locking grooves prevent connector rotation and
retain its locking ability independent of tension or stress caused by the cables or wires,
eliminating the possibility of the connector assembly coming apart.

Essential Tips for Selecting Mil-Spec Backshells

Engineers must consider the specific interconnect system design or application at hand when
selecting a suitable connector backshell. For example, some designs require cables with larger
diameters to be terminated in a smaller connector shell size, while others require thick, steel-
braided cable or shielding, which in turn requires a longer or more robust cable clamp.
Additionally, if many wires in an application need routing, an extender backshell might be
necessary.

Engineers also need to consider a backshell’s cable entry dimensions. Some backshells
include a grommet or boot that needs to be sized to the outside diameter (OD) of the cable or
wire bundle. The cable clamp portion of a backshell can also vary in length to accommodate a
large number of wires but this also typically increases the size of the backshell itself. Further, if
the wires or cable require a 45° or 90° bend, incorrect backshells can be problematic in
applications that also require cabling to be against a bulkhead or a cable service loop.

Small nuances like these might not seem very important, and are frequently overlooked, but the
probable impact of this type of oversight can lead to dire consequences, including project
delays, increased cost, and even premature connector failure.

In addition to connector shell size, engineers should consider the following when choosing a
backshell:

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 What are the material/finish specifications fo the mating connector?
What level of environmental protection is required?
What level of EMI shielding is required?
What amount of strain relief is needed to protect the conductor terminations?
What is the temperature range of the application?
Is repairability a design requirement?
Are there any size or shape constraints requirements?
Can there be any metal, or are reducing weight and preventing corrosion part of the
requirements?

Types of Circular Connector Backshells

Backshells are available in many configurations to match any Mil-Spec connector. Common
configurations include: strain relief, extender, environmental, EMI/RFI cable sealing, and
banding and crimping.

Mil-Spec connectors are typically employed in mission-critical applications and, depending on

the application, backshells are available in straight, 45°, and 90° configurations capable of
supporting standard connector shell sizes 4 through 48. Backshell configurations can also
include a cost-effective cable holding option, have an environmental and non-environmental
rating, and offer EMI/RFI protection. For example, Glenair Qwik-Ty® strain reliefs use a tie
strap to secure cables or wires, and are offered in M85049/43 (45°), M85049/51 (90°), and
M85049/52 (straight) self-locking or non-self-locking features with an optional ground lug.

Backshells are also available in several finishes, including: black anodized, nickel fluorocarbon
polymer, olive drab cadmium, zinc nickel, electroless nickel, and pure dense electrodeposited
aluminum. The finish on the M85049/2 in Figure 2 is cadmium olive drab over electroless
nickel, the combined materials benefits of which provide the part with a 1,000-hour salt spray
protection rating.

Figure 3: This M85049/2 backshell

clamp from Amphenol Pcd is a cost-
effective cable holding option for
applications in which environmental
protection is not a concern, but reduced
weight is a major consideration.

Mil-Spec connectors connect and

protect sensitive electronic equipment
used in mission-critical applications
ranging from commercial and military
avionics to unmanned robots and
satellites. Backshell clamps not only
neatly arrange cables post-termination
in these applications, but also provide good strain relief at the termination area, and can even
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provide environmental, EMI, and RFI protection. So, to avoid making incorrect assumptions
that could lead to costly delays and potential product failures during the connector selection
process, engineers and buyers should properly consider all of the backshell requirements early
in the project.

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