What is HX5?
HX5 is Alpine Advanced Material’s flagship multi-scale reinforced polymer that delivers the strength of aluminum at half the weight. With superior environmental resistance, EMI shielding, and injection moldability, HX5 is transforming aerospace components across commercial, defense, and space applications.
How Much Weight Can You Save?
By manufacturing connector components with HX5, we’re reducing weight, extending product life, and enabling greater operational efficiency across the fleet. Explore the difference HX5 makes across multiple aerospace connector families, and scroll down to see additional performance benefits as a result of HX5's material properties.
| Product Family | Original Weight (Material) | HX5 Weight | Weight Saved |
|---|---|---|---|
| 987 Series Connector | 167g (Stainless Steel) | 30g | 137g |
| ARINC 600, Size 2 | 224g (Aluminum) | 112g | 112g |
| DMCM | 172g (Aluminum) | 86g | 86g |
987 Series High Voltage Connector
Original Weight: 167g (Stainless Steel)
HX5 Weight: 30g
Weight Savings: 137g
Performance Benefits:
-
Corrosion resistance prevents degradation from fuels, moisture, or solvents
-
EMI shielding protects nearby avionics from high-voltage magnetic interference
-
High surface tension ensures compatibility with electroless nickel-over-copper plating for conductive path
ARINC 600, Size 2
Original Weight: 224g (6000-series Aluminum)
HX5 Weight: 112g
Weight Savings: 112g
Performance Benefits:
-
Resistant to corrosion from moisture and solvents
-
Injection molded: significantly faster and more scalable than machining
-
Low weight enables system-level fuel and emissions savings
Savings per Ship Set: ~88.5–120 lbs (narrow vs. wide-body aircraft)
DMCM
Original Weight: 172g (6000-series Aluminum)
HX5 Weight: 86g
Weight Savings: 86g
Performance Benefits:
-
High plating compatibility as a result of high surface tension
-
Rapid molding cuts production time by 10x vs. machining
-
Chemically stable and corrosion resistant
Want to explore how these parts can improve your design?
Reach out to TE for comprehensive specs and assistance.
Proven Performance in Demanding Aerospace Environments
HX5 isn’t new to flight. Originally developed for military aircraft, HX5 has been in service since 2015—housing critical system electronics in high-stakes, high-vibration environments. With flight heritage spanning space, vertical lift, fixed-wing, and unmanned platforms, HX5 brings a trusted track record to its new role in aerospace connectors.
.png?width=1350&height=1080&name=electronics%20box%20(2).png "electronics box (2)")
In the Air, or in Orbit
HX5 also meets the rigorous demands of space applications. From extreme temperatures to high radiation exposure, HX5 delivers proven performance in the harshest environments. It offers:
- Exceptional Dimensional Stability: HX5 maintains its shape and precision across a wide thermal range, with a CTE of 3.8 × 10⁻6 m/m/°C —an order of magnitude lower than 6061 aluminum’s 2.36 × 10⁻⁵ m/m/°C. This reduced thermal expansion minimizes distortion, ensuring reliable performance in extreme environments.
- Radiation Resistance: With a Total Ionizing Dose (TID) resistance of 5 million rads (Si), HX5 outperforms many polymer-based materials in long-term exposure to space radiation.
- Low Outgassing: HX5 exceeds NASA's rigorous outgassing standards, with a Total Mass Loss (TML) of 0.217% and Collected Volatile Condensable Materials (CVCM) of just 0.0001%, minimizing the risk of contamination for sensitive space instrumentation.
