Military Grade 1/4"-28 Pass-Through Stud for Drones – Small Footprint, Great Performance
Military drone and UAV electrical systems require compact, lightweight components capable of performing in demanding flight environments. When a military contractor needed a smaller pass-through stud capable of supporting high current requirements, GEP Power Products reconfigured an existing PTX pass-through stud design to help meet strict size, weight and performance expectations.
The Need for a Smaller Military-Grade Pass-Through Stud
A military contractor contacted GEP Power Products about the company’s existing PTX pass-through studs. The pass-through device would be used as a power feed source in UAV bulkheads or firewalls. The client required a reconfigured version of GEP’s standard military-grade pass-through device for military drone aircraft. The new version needed to meet strict weight constraints while supporting high current transfer through a significantly reduced part size. The application requirements included:
- A compact 1/4"-28 pass-through stud configuration
- Reduced part size for UAV applications
- Lower weight to support drone aircraft design requirements
- 200-amp current capacity
- Physical integrity for demanding use
- Support for assembly torque requirements
- Suitability for UAV bulkheads or firewalls
Power Distribution Needs in Military UAV Applications
In modern warfare, an increasing number of military missions are accomplished using drones or UAVs. A UAV is a pilotless aircraft flown through a pre-programmed flight pattern or a more complex automation system. UAVs support strike-zone, combat, surveillance and high-risk fly zone missions without putting a human pilot in the aircraft. Unmanned applications depend on sophisticated onboard electrical systems built to support mission-critical functions in compact aircraft platforms. From communications to power, each electrical component needs to be as small and lightweight as possible while still providing reliable performance.
Reconfiguring the Existing PTX Pass-Through Stud Design
GEP Power Products reviewed the design of its existing larger PTX pass-through studs to develop a viable solution for the military contractor’s UAV application. The team improved the standard stud design by combining materials selected for strength, conductivity, insulation and reduced weight. The reconfigured pass-through stud included:
- Stainless steel exterior: Added for strength, corrosion resistance and physical integrity.
- Copper inner core conductor: Used to meet the specified current capacity.
- Nylon overmolded body and mounting unit: Added for insulation, mechanical strength and decreased weight.
This material combination allowed GEP to reduce the part footprint while supporting the current capacity and durability requirements for the application.
Performance Without Access to Full Test Specifications
For security reasons, GEP Power Products was not provided with the client’s test specifications. Even with limited testing details available, the military-grade pass-through stud met and exceeded the application requirements when tested by the client. This result demonstrated GEP’s ability to adapt an existing power distribution component for a highly specialized UAV application while working within limited program information.
Key Product Features
The military-grade 1/4"-28 pass-through stud was developed to support compact, high-current power transfer in drone aircraft applications. Key features include:
- Small-footprint design: Reconfigured for use in military drone and UAV platforms.
- 200-amp current capacity: Designed to pass the specified current through a reduced part size.
- Stainless steel exterior: Supports strength, corrosion resistance and physical integrity.
- Copper inner core conductor: Provides the conductivity needed for high-current performance.
- Nylon overmolded body: Supports insulation, mechanical strength and weight reduction.
- Bulkhead and firewall compatibility: Built for use as a power feed source through UAV barriers.
- Military-grade performance: Tested by the client and found to meet or exceed application requirements.
Custom Power Products for Specialized Applications
GEP Power Products is an ISO 9001:2015 certified company and is also RoHS compliant. The company manufactures power products used for distribution, protection, storage, switching and termination applications. When an off-the-shelf component does not meet the needs of a specialized vehicle, drone or power distribution application, GEP offers on-site engineering expertise to develop a solution suited to the requirement.
