Let’s Talk Technical: Rugged Connectors, 48V Systems & Data Centers on Wheels | DigiKey

Modern vehicles are evolving into something far beyond transportation, they’re becoming rolling networks of high-speed data, electrified systems, and increasingly intelligent architectures. In this episode of Let’s Talk Technical | DigiKey, Sean Luke sits down with Kirk Ulery from Molex’s Transportation Systems Business Unit to explore how rugged automotive connectors are adapting to support this transformation and how those same solutions extend well beyond traditional vehicle applications. Kirk shares the story behind Molex’s Beyond the Garage series, which highlights a simple but powerful idea: connectors originally engineered for harsh automotive environments often deliver exceptional value in non-automotive markets. Automotive components are designed to survive extreme vibration, temperature swings, moisture, chemicals, and mechanical stress. When you apply that level of durability to applications like industrial dishwashers, agricultural equipment, marine systems, or construction machinery, you gain reliability advantages that dramatically reduce downtime and long-term costs. One standout example is the NX 150 mid-current, mid-voltage system being used to seal control boards in industrial dishwashers, protecting electronics from water intrusion and eliminating expensive repairs. The conversation then shifts to one of the most important transitions happening in transportation today: the move from 12V systems to 48V architectures. As vehicles and machinery adopt higher voltage rails to support electrification, engineers must think carefully about creepage, clearance, hot plugging, and plating materials. Moving to 48V dramatically reduces current requirements, enabling smaller terminals, lighter wire gauges, simplified routing, and lower overall system weight. But those benefits come with new design considerations that must be addressed to ensure safety and long-term reliability. Beyond power delivery, modern transportation platforms are managing extraordinary amounts of data. With surround-view cameras, ADAS systems, and increasing levels of autonomy, vehicles are effectively becoming data centers on wheels. Kirk explains how innovations like Power over Coax, Mini-FAKRA/HFM connectors, and Single Pair Ethernet enable high-speed data transmission while maintaining signal integrity in rugged environments. These technologies support the zonal architectures now emerging in automotive design, where localized controllers reduce wiring complexity and communicate across high-speed backbones to improve redundancy and scalability. As vehicles move toward software-defined models, the interconnect strategy becomes foundational to long-term performance and upgradeability. Throughout the discussion, one theme remains consistent: start with the environment. Whether designing for a vehicle brake system, a marine application, a factory floor, or an outdoor security installation, understanding the electrical and mechanical stresses your system will face is the key to selecting the right connector. With thousands of Molex interconnect solutions available through DigiKey, the challenge isn’t availability, it’s identifying the best fit for your specific application. If you’re designing for rugged environments, exploring 48V systems, or building architectures that must handle both power and high-speed data, this episode offers valuable insights from decades of automotive experience applied across industries. Watch now to see how interconnect innovation is driving the next generation of electrified and data-driven systems.