Topic Questions
Could you tell us more about “Beyond the Garage” and why you felt the need to go forward with this series?
- Although our transportation systems group has traditionally designed products for automotive use, this role focuses on expanding those solutions into non-automotive applications through distribution partners. To shift thinking beyond cars, we developed the concept “Beyond the Garage,” reflecting our goal of applying automotive-designed parts to broader uses. We’ve already launched an initial “season” on YouTube and recently filmed a new series set to release throughout 2026.
What’s an application from “Beyond the Garage” that has caught your attention? What was something unique that you found?
- As we expand beyond automotive, we continue to see exciting new applications for our products. In the series, we explain why our parts were originally developed for vehicles - designed to withstand harsh automotive environments - and encourage designers to consider whether their own applications demand similar durability. A key example is our NX 150, a widely used mid-current, mid-voltage automotive system and our largest global product line. We now supply it to an appliance manufacturer for use in industrial dishwashers, where its sealed design protects the control board from moisture. Unlike previous exposed circuit boards that failed when wet, the sealed NX 150 prevents costly damage - even if a hose breaks - demonstrating the value of applying automotive-grade solutions beyond the garage.
Engineers often face failures due to vibration, thermal cycling, and corrosion. How do you define ‘rugged’?
- For us, “rugged” refers to the harsh environments a system must endure. The same M150 connector used in fuel injector modules is also used in anti-lock brake systems mounted on vehicle wheels - components that must withstand snow, water, vibration, and constant impact, especially in places like Detroit where potholes are common. These real-world automotive conditions demonstrate the durability of our connectors. That same decades-long vehicle experience makes them well suited for demanding applications in industries like construction and material handling.
What are some other industries that require rugged connectors?
- Agriculture is a strong secondary market for us, and we currently supply products to most major farm equipment manufacturers in North America and globally. We also serve construction applications - such as backhoes and forklifts - that operate in harsh conditions. Beyond that, we’re expanding into marine markets, where constant water exposure and heavy vibration from rough conditions create rugged environments well suited for our products.
With the shift to 48V systems, what design considerations (like creepage, clearance, and materials) become critical?
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At 48V (what we call mid-voltage, 20–60V), one of the biggest design considerations is meeting creepage and clearance requirements - the distances across insulating material and between pins that prevent arcing. While most traditional automotive systems operate at 20V or less and don’t require as much attention to these factors, 48V systems demand stricter spacing and protection, especially to manage issues like hot plugging and arcing. We design our connectors with appropriate plating and features such as make-first/break-last configurations to handle these conditions safely and cost-effectively.
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The push toward 48V is being driven by increasing electrification - not just in fully electric vehicles, but also in internal combustion platforms adding electric power steering, turbocharging, and brake systems. Moving from 12V to 48V either quadruples available power (per Ohm’s law) or allows the same power at significantly lower current - reducing current from around 80 amps to 20 amps. This enables smaller terminals and wires, lowering cost, weight, and packaging complexity while improving overall system efficiency.
As data rates push to 10Gbps and beyond (for computer vision and ADAS needs), what innovations in connector design help maintain signal integrity?
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We’re focused on two main areas: high-speed camera connectivity and in-vehicle networking. As backup cameras became mandated in 2015, the industry shifted from multi-pin analog systems to power-over-coax solutions using FAKRA connectors. We’ve advanced this with our mini-FAKRA (HFM) system, which is smaller, supports multiple connections in a single housing, and delivers data speeds up to 20 Gbps—ideal for today’s surround-view and ADAS platforms that may use 4 to 13 cameras per vehicle. These higher speeds also support features like 5G connectivity and vehicle-to-everything (V2X) communication.
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The second focus is Ethernet-based vehicle networking. While traditional Ethernet uses two twisted pairs, automotive increasingly relies on single-pair Ethernet (IEEE 802.3-based), allowing transmit and receive over one pair of wires. This supports the growing “data center on wheels” reality of autonomous and advanced safety systems. We’re also seeing a shift to zonal architecture, which reduces wiring length by grouping sensors locally and linking zone controllers via high-speed backbones. All of this enables greater redundancy, improved efficiency, and the evolution toward the software-defined vehicle, where features can be added and updated over time through software.
YouTube Video Sources
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Video on this Topic
Let’s Talk Technical: Rugged Connectors, 48V Systems & Data Centers on Wheels | DigiKey
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Molex
Molex believes in the transformative power of creating connections. As a leading global provider of connector solutions, Molex brings engineering excellence, trusted relationships and an unparalleled commitment to quality and reliability to help customers across industries improve lives. Trusted for more than 80 years, Molex offers world-class design, manufacturing and a portfolio of 100,000+ innovative products. We’re doing more than developing solutions, we’re Creating Connections for Life.