UAVs are becoming smarter and more modular. But in defense applications, they also need to be more rugged, secure, and reliable, often in contested, high-stakes environments where failure is not an option.
Military drones operate beyond visual line of sight (BVLOS), in GPS-denied zones, under extreme weather, and in high-EMI regions. These conditions stress every subsystem — especially the cable assemblies and connectors that power and link mission-critical electronics.

Inside a Military UAV: The Interconnect Challenge

Modern military drones are densely packed with advanced electronics:

• Electro-optical and infrared (EO/IR) gimbals
• Tactical radios and encrypted comms
• Global Navigation Satellite System (GNSS) denied navigation systems
• AI-powered sensor fusion platforms
• Real-time onboard video processing

Each subsystem depends on uninterrupted data, control, and power delivery. And that depends on one thing: the quality of the interconnect design.

Key Requirements:

Micro Coax: The Backbone of UAV Sensor Systems

Military drones depend on micro coaxial cables to transmit high-speed video and sensor data with minimal signal loss. These cables are typically routed from:

• Gimbal-mounted cameras to onboard recorders
• GNSS and RF modules to processors
• flight computers to secure downlink systems for real-time data transmission

Mitas Electronics supplies custom-terminated micro coax assemblies, built to support protocols like USB 3.1, HDMI, MIPI, and LVDS, enabling routing in tight compartments.

We work with miniature RF connectors including:

• I-PEX MHF series
• JAE and Hirose board-level interfaces
• Custom EMI-sealed connectors with over molding

Power and Control Interconnects for Harsh Conditions

It’s not just about data. Power and command lines must survive shock, vibration, and temperature cycling. Mitas interconnects use high-grade materials like:

• FEP, ETFE, or cross-linked polyolefin jackets
• Silver- or tin-plated copper conductors
• Spiral, braided and/or foil EMI shields

Harnesses are built to spec for MIL-DTL, IPC/WHMA-A-620, and/or DO-160G standards as required.

Real-World Application: Tactical Surveillance Drone

Platform: Fixed-wing Intelligence, Surveillance, and Reconnaissance (ISR) drone designed for hand-launch in tactical environments

 Mission: Day/night surveillance and battlefield mapping
 Subsystems:

• Dual Electro-Optical/Infra-Red (EO/IR) cameras
• Tactical radio with satellite communication (SATCOM) fallback
• Secure data links for telemetry transmission
• Inertial navigation

Mitas Solution:

• Micro coax video lines with fine pitch connectors
• Shielded wire for CAN and UART buses
• EMI-isolated power cable with multi-branch routing
• Modular inline connectors for easy field replacement

Result:
A complete interconnect solution that ensures uninterrupted data flow from sensors, reliable command/control transmission, and stable power delivery even in high-vibration, and thermally volatile missions. The optimized harness design improved signal integrity, enhanced operational uptime, and simplified field maintenance, directly contributing to greater mission reliability and overall system readiness.

Why Mitas for Defense UAV Projects?

At Mitas Electronics, we understand that military UAVs operate in environments where failure is not an option. Our interconnect solutions are engineered to deliver continuous data transmission, resilient power delivery, and uncompromised signal integrity all in the most demanding conditions.

We offer:

– Custom Micro Coax & Twinax Assemblies
 Built for high-frequency protocols (MIPI CSI-2, USB 3.1, LVDS, RF), our assemblies minimize signal loss while meeting the tight routing and shielding demands.

– EMI-Optimized Cable Design
 Utilizing spiral, foil, and braided shields, we design harsh EMI environments reducing signal disruption from radar, radios, and onboard processors.

– Support for Miniature Connectors & Lightweight Harnessing
 We integrate I-PEX, JAE, Hirose, and custom interfaces into space-constrained systems, supporting UAV weight and form factor requirements.

– U.S.-Based Engineering with Global Manufacturing Access
 From MIL-STD to DO-160G compliance, we ensure defense-grade reliability with scalable production and responsive support.

Enabling the Future of Flight

From defense to energy, from agriculture to urban logistics, UAVs are changing how we operate in the world:

• In defense, they reduce risk and extend reach
• In energy, they inspect remote infrastructure with real-time data feedback
• In agriculture, they apply precision spraying and data-driven crop analysis
• In advanced air mobility, they are paving the way for autonomous logistics and delivery

Behind each of these breakthroughs is a web of electrical connections, carrying data, power, and control signals across systems. Those connections must be light, reliable, and resilient.

That’s where Mitas Electronics quietly supports the mission.

UAVs are getting faster, smarter, and more modular, but none of them work without dependable interconnects. While they may be hidden under hatches and inside enclosures, cables and connectors play a frontline role in UAV success.

Ready to take your UAV systems to the next level?
Partner with Mitas Electronics and build the interconnect foundation your mission deserves.
Let’s engineer what’s next together.