# PCB Connectors That Survive Space, Shock & 500 Thermal Cycles

- Show: [OnTrack](https://hardwarepodcasts.com/podcast/ontrack)
- Published: 2026-10-07
- Length: 35m
- Episode: 357
- Page: https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles
- Listen: https://podcast.altium.com/e/pcb-connectors-that-survive-space-shock-500-thermal-cycles/

## Summary

Shane Dabrowski, a Field Applications Engineer at Samtec, explains how the company’s Severe Environment Testing (SET) and MIL-DTL-55302 lot-based testing validate standard connectors for military, aerospace, and LEO satellite applications. He details why solder joint fractures, rather than pin failure, are the primary issue during extreme thermal cycling from -65°C to 125°C, and discusses tin whisker mitigation through custom plating. The conversation covers the shift toward high-speed combo signal-and-power connectors, the use of C-Ray mezzanine connectors in VPX systems, and the industry's move toward column solder joints to replace BGA balls for better signal integrity at 224G speeds.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles#t=0) Introduction: Shane Dabrowski and Samtec Background
- [2:59](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles#t=179) Samtec Severe Environment Testing (SET) and VITA 47 Compliance
- [8:25](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles#t=505) Custom Plating and Tin Whisker Mitigation Strategies
- [15:10](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles#t=910) MIL-DTL-55302 Lot-Based Testing and Failure Modes
- [19:22](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles#t=1162) C-Ray Connectors and VPX Mezzanine Applications
- [27:01](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles#t=1621) High-Speed Data Rates, Power Density, and 224G Connectors
- [31:14](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles#t=1874) Column Solder Joints vs. BGA Balls for Signal Integrity

## Topics

- [PCB design & layout](https://hardwarepodcasts.com/topic/pcb-design)
- [Mechanical engineering](https://hardwarepodcasts.com/topic/mechanical-engineering)
- [Manufacturing partners & offshoring](https://hardwarepodcasts.com/topic/manufacturing-partners)
- [Certification & compliance](https://hardwarepodcasts.com/topic/certification-and-compliance)

## Most relevant to

early-stage companies

## Mentioned

- Samtec (company)
- Northrop Grumman (company)
- Micron (company)
- VITA 47 (other)
- MIL-DTL-55302 (other)
- C-Ray (product)
- MicroPower (product)
- VPX (other)
- FMC (product)
- QMC (product)
- Accelerate (product)
- Sci-Fi HD (product)

## Related episodes from other shows

- [The Spark Gap - Episode 40](https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40) (The Spark Gap)
- [Building Together: Oxide and Samtec](https://hardwarepodcasts.com/podcast/oxide-and-friends/2023-05-16-building-together-oxide-and-samtec) (Oxide and Friends)
- [Toasted Marshmallow Connectors](https://hardwarepodcasts.com/podcast/the-amp-hour/2021-09-20-toasted-marshmallow-connectors) (The Amp Hour)
- [Idiographical Interconnect Intorsion](https://hardwarepodcasts.com/podcast/the-amp-hour/2012-04-16-idiographical-interconnect-intorsion) (The Amp Hour)
- [Ep 313: Capacitor Plague, Wireless Power, and Tiny Everything](https://hardwarepodcasts.com/podcast/hackaday-podcast/2025-03-21-ep-313-capacitor-plague-wireless-power-and-tiny-everything-cb8186ab) (Hackaday Podcast)

## Citing this page

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