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High-Voltage Interconnects for Aerospace

Caton designs and manufactures custom high-voltage cable assemblies and RF interconnect for commercial and military aerospace platforms — avionics, satellite communications, airborne command and control, aerostat surveillance, and aircraft electrical systems. AS9100 certified, ITAR registered, with the engineering continuity that long-program-life aerospace platforms require. Engineering-led since 1973.

AS9100 ISO 9001 ITAR Registered CMMC AS5553 AS9102 FAI
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What we do

The engineering team responsible for the high-voltage interconnect, across the program lifecycle

We are the engineering team responsible for the high-voltage interconnect on aerospace platforms where the part qualified at design release has to be available, identical, and engineering-supported decades later. Our customers come to us when off-the-shelf connectors won’t hold the qualification, when the program needs an engineering-accountable supplier with full design ownership, or when a fielded platform needs sustainment from a US-based, AS9100-certified manufacturer.

We own the full interconnect: cable design, connector design, in-house overmolding, and complete electrical qualification under one roof — across the program lifecycle, from design release through sustainment and obsolescence management.

Engineering capability

High-voltage and RF design, qualification, and configuration control

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Custom interconnect engineered to the aerospace qualification regime — not adapted from commercial parts. RF distribution, high-voltage signal and power, multi-port custom geometries, and integrated mechanical features for airframe mounting, all designed under AS9100 controlled processes.

Capability
High-voltage and RF design, in-house

Custom cable and connector design from 1 kV to 250 kV, plus RF distribution and signal interconnect. Finite element analysis using Electro V10.2 for electrical field optimization, corona mitigation, and dielectric stress analysis at altitude.

In-house overmolding

Overmolded interconnects engineered for the airframe environment — vibration, thermal cycling, altitude derating, and long-term insulation aging. Overmold geometry, materials, and processing are part of the electrical design.

Capability
Test capability on-site

Corona inception and extinction, partial discharge, hi-pot, insulation resistance, dielectric withstand, leakage current, and thermal cycling — all in-house. Altitude testing to 70,000 ft in our Tenney altitude chamber, including corona-at-altitude characterization. Manufacturing engineers work at benches on the production floor, alongside the test stations and the build, so design issues get caught and resolved in real time.

Qualification programs managed across accredited labs

Caton designs to and manages qualification programs against the standards aerospace programs require — DO-160 airborne environmental, MIL-STD-461 EMI/EMC, MIL-STD-810 environmental, MIL-STD-704 aircraft electrical power, NASA EEE-INST-002 for space, and AS9102 first article inspection. Environmental qualification is conducted at accredited test labs as part of the program engagement, with Caton managing the test plan, witnessing, and report integration.

Capability
Configuration control across the program lifecycle

Locked configurations at design release. Controlled change management. Build records, material certifications, and test data archived for the life of the program. Risk-based thinking under AS9100. Counterfeit electronic parts mitigation under AS5553.

Materials engineered for the airframe

PEEK, FEP, silicone, stainless steel, and aerospace-grade alloys selected per application and qualified per program. Materials decisions made by Caton engineering, not driven by catalog availability.

Programs and applications

Where Caton interconnect is specified today

Commercial aerospace avionics — RF distribution, signal interconnect, and high-voltage assemblies for navigation, communications, and flight management systems on commercial transport platforms.
Satellite communications — high-voltage interconnect for ground-based and airborne satellite communications terminals on long-running military communications platforms.
Airborne command and control — high-voltage interconnect for airborne C2 platforms where electrical performance and long-term reliability are critical to mission availability.
Aerostat and lighter-than-air surveillance platforms — high-voltage and signal interconnect for tethered and untethered surveillance aerostats, engineered for long-duration unattended operation at altitude.
Aircraft electrical and ignition systems — high-voltage assemblies for engine ignition, propulsion firing circuits, and aircraft electrical power distribution.
Space-rated interconnect — high-voltage cable and connector assemblies engineered for orbit-life thermal cycling, radiation environment, and multi-decade mission duration.
Industry leaders who trust Caton

Aerospace relationships sustained across decades of program lifecycles

HoneywellLockheed MartinCollins Aerospace

Components specified into commercial aerospace avionics, satellite communications platforms, airborne command and control systems, and aerostat surveillance programs. Specific program references available under appropriate disclosure.

Why aerospace engineers choose Caton

Engineering continuity for programs that run for decades

Reason
Engineering continuity for long-program-life platforms

Aerospace programs run for decades. The cable assembly qualified at design release has to be available, identical, and engineering-supported in year twenty. Locked configurations, controlled change management, and same-team engineering across the program lifecycle.

Full traceability and AS9102 first-article rigor

Every Caton assembly ships with material certifications, process records, electrical test data, and configuration control records. AS9102 first article inspection on new programs. Build records archived for the life of the program.

Reason
Obsolescence management is part of the engagement

When a component goes end-of-life or a process changes, Caton’s engineering team manages the transition under controlled change. Customers don’t lose the qualification because a sub-tier vendor discontinued a part.

Engineering-led since 1973

Family-owned, US-manufactured, AS9100-certified, ITAR-registered. The same engineering team across decades of aerospace programs. The supplier you qualify today is the supplier still building your part in year twenty.

Engagement

Working with Caton on an aerospace program

We’re built for the design phase of new aerospace programs and for the sustainment phase of fielded platforms where the original supplier can no longer build, qualify, or support the part. We respond to RFQs at the development, qualification, and production stages, and we support sustainment, obsolescence management, and configuration recovery on legacy programs.

Other markets

Explore other industries we serve

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High-voltage interconnect for missile defense, directed energy, hypersonics, and space-based defense.
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Precision HV interconnects and vacuum feedthroughs for semiconductor capital equipment.
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Scientific
Scientific & Research
Custom HV assemblies for research platforms operating at extreme voltages.
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Talk to engineering about your aerospace program

Your design engineer talks to our design engineer. New program development, qualification, sustainment, or obsolescence management on fielded platforms — the conversation starts at the engineering bench.

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