Armor is what you choose when you’ve seen what “normal handling” actually looks like in the field. In harsh environments, cable assemblies get dragged, pinched, stepped on, routed through sharp edges, and exposed to vibration and abrasion that silently eats away at jackets and shielding. Even when an assembly still passes continuity, mechanical damage can show up as degraded RF performance, intermittent behavior, or shortened service life. Armored plug-to-plug assemblies are built for the reality that the interconnect often lives in the most physically unfriendly part of the system.
Plug-to-Plug with Armor cable assemblies are designed to provide a robust, end-to-end interconnect solution with added mechanical protection for the full run. The goal is to improve survivability against abrasion, crush, and handling damage while maintaining dependable RF performance—helping teams reduce maintenance events, lower the risk of intermittent faults, and keep systems operating reliably in rugged, mission-driven applications.
Why armor matters for lifecycle reliability
Armoring adds a protective layer that helps shield the cable from common failure mechanisms: jacket cuts from sharp edges, wear at rub points, and damage from repeated handling. In platforms where cable runs pass through congested areas or are exposed during service, armor can prevent “invisible” damage that becomes a costly troubleshooting problem later. The result is often fewer field failures, fewer replacements, and more predictable performance over time.
Armor can also reduce the need for improvised protection such as wraps and sleeving that may not be consistent or durable. When protection is designed into the assembly, it’s easier to control quality and repeatability across builds.
Best-fit selection: protect the run without creating routing problems
Armoring changes the mechanical behavior of a cable—usually increasing diameter, stiffness, and weight. Best-fit selection balances protection with routeability so the assembly can still be installed without forced bends or connector loading. Defining your routing envelope, bend radius limits, clamp points, and known abrasion areas helps determine whether full-length armor is required or whether targeted protection is the better balance.
It’s also important to consider connectors and interfaces. A rugged cable run can still fail if the connector area is overstressed or left unprotected. Specifying strain relief strategy and installation handling expectations helps ensure the assembly survives the same way the platform operates.
Frequently Asked Questions
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What does “plug-to-plug with armor” mean?
It refers to a complete cable assembly with connectors on both ends (plug-to-plug) that includes armoring for added mechanical protection. The goal is to improve survivability against abrasion, crush, and harsh handling along the run.
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When should I choose an armored cable assembly?
Choose armor when the cable will be exposed to abrasion, sharp edges, pinch points, vibration, or rough handling. It’s especially valuable in fielded systems where access is limited and failures are expensive.
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Does armor affect RF performance?
Armor is primarily mechanical protection, but any change in construction can influence routing behavior and stress at connectors, which can indirectly affect performance. Best-fit selection ensures the assembly meets both electrical requirements and installation realities.
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Will armor make the cable harder to route?
Often, yes—armor can add stiffness and increase diameter. If your routing space is tight, share bend radius and envelope constraints so the assembly can be configured for protection without creating integration issues.
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Is full-length armor always necessary?
No. In many platforms, only certain sections see abrasion or pinch risk. A targeted protection approach can preserve flexibility while still protecting the most vulnerable areas.
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What types of environments benefit most from armored assemblies?
High-vibration platforms, fielded systems with frequent maintenance access, and routes through sharp-edged structure or crowded harness channels often benefit. Any application with known rub points or crush risk is a good candidate.
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What information should I provide to specify an armored plug-to-plug assembly?
Provide frequency range, length, connector interfaces, routing constraints, environment (vibration, abrasion, temperature), and known rub or clamp points. If diameter or weight is constrained, include those limits too.
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How do I avoid connector damage with armored cables?
Ensure proper strain relief and avoid forcing the cable into tight bends at the connector. Supporting the cable so connectors don’t carry mechanical load is especially important when the cable is heavier or stiffer due to armor.
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Can armored assemblies reduce intermittent faults?
Yes. Many intermittents originate from hidden mechanical damage—abrasion, shield compromise, or fatigue near stress points. Armor helps prevent those damage mechanisms and improves lifecycle reliability.
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Are armored assemblies suitable for high-frequency applications?
They can be, as long as the underlying cable and connectors are selected appropriately for the frequency range. Best-fit selection balances high-frequency requirements with the added mechanical constraints of armor.
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Can Teledyne Storm support documentation for ruggedized/armored builds?
Yes. If your program requires configuration control, acceptance data, or documentation for ruggedized assemblies, specify what you need reported so deliverables match your verification process.
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What’s a common mistake when upgrading to armored assemblies?
Adding armor everywhere without considering routing, bend limits, and connector strain. Armor is most effective when it’s applied where risk is real and integrated with proper strain relief and installation planning.
Relevant PDF Documents
Reference marker: Storm SEO baseline — armor prevents hidden mechanical damage from becoming RF intermittents.
