【aerospace】Custom RF Connectors for In-Flight 5G and Wi-Fi: Low Loss, High Reliability

Custom RF Connectors for In-Flight 5G and Wi-Fi: Low Loss, High Reliability

Introduction

As the global aviation industry embraces digital transformation, in-flight 5G connectivity is evolving rapidly, enabling faster and lower-latency wireless networks for both commercial and military aircraft. According to market forecasts, the global in-flight connectivity market is expected to maintain steady growth over the next five years, driven by increasing passenger demand for high-speed Wi-Fi, upgraded in-flight entertainment and business applications, and enhanced fleet data analytics and remote monitoring.

With the advancement of 5G millimeter-wave (mmWave) technology, airborne communication systems require higher bandwidth and ultra-low latency, while also facing harsh environmental challenges at high altitudes. From external 5G antennas to internal Wi-Fi routers, the entire system demands RF connectors with superior reliability, low signal loss, and high interference resistance. Ensuring stable 5G signal transmission under flight conditions has thus become a critical issue in airborne network development.

Customer Challenge: Unstable In-Flight Wi-Fi—What Went Wrong?

Our client, a developer of airborne communication equipment including 5G antennas and in-cabin Wi-Fi routers, received feedback from an airline regarding unstable Wi-Fi performance. The connection issues negatively impacted both entertainment and business functions, resulting in poor passenger experiences.

Initially, the client suspected a software or equipment malfunction. However, after in-depth analysis by their technical team, the root cause was traced to a less obvious but critical component: the high-frequency RF connectors within the aircraft's 5G antenna system.

Key issues identified:

• Excessive Signal Loss at High Frequencies: While 5G mmWave (above 24 GHz) offers extremely high speeds, it is prone to attenuation and poor penetration. The existing RF connectors performed poorly in terms of insertion loss, which was further exacerbated by conditions at 30,000–40,000 feet, resulting in unstable signals.
• Severe Environmental Interference: Mounted externally on aircraft fuselage or wings, 5G antennas face high-altitude wind, humidity changes, and electromagnetic interference (EMI) from radar and navigation systems. Moisture absorption in clouds or rain further weakens mmWave signals.
• Space and Weight Constraints: The in-cabin Wi-Fi router required compact installation. The original connectors were too bulky, offered insufficient shielding, and added unnecessary weight—limiting space utilization and worsening interference.

The client urgently needed a custom RF connector solution that offered low loss, high shielding, miniaturization, and aviation-grade reliability.

Our Solution: Stable 5G Signal at 30,000 Feet

To address the challenges of signal loss, EMI, and installation constraints, CHIN NAN developed a fully customized RF connector solution for both airborne 5G antennas and in-cabin Wi-Fi routers, precisely tailored to meet aviation-specific requirements.

1. Low-Loss RF Connector Design for Enhanced Signal Transmission

We optimized the internal structure with high-precision conductors and low-loss materials to reduce insertion loss to below 0.2 dB—a 60% improvement. Impedance matching was tuned for mmWave frequencies above 24 GHz, significantly reducing return loss and improving 5G antenna reception, resulting in more stable Wi-Fi in the cabin.

2. IP68 Waterproofing & EMI Shielding for Harsh Conditions

The connector housing features an IP68-rated waterproof design, ensuring performance in high-altitude fog or rain. Inside, multi-layer shielding blocks external EMI from radar and navigation systems, maintaining signal clarity and antenna system efficiency.

3. Compact and Lightweight for Aircraft Interior

Designed with high-density layouts, our RF connectors are 30% smaller and 25% lighter than previous models—ideal for space-restricted cabin installations. Despite the reduced size, they maintain high-frequency performance without compromising signal stability.

4. Paired with Low-Loss Coaxial Cables for System Integrity

We also provided specially designed low-loss coaxial cables to reduce mmWave signal attenuation over distance, ensuring reliable transmission from the antenna to the router. Flexible cable design enables easy routing and maintenance inside complex aircraft structures.

Measurable Value: Smoother Connectivity, Happier Passengers

The results of this collaboration went beyond technical improvements—it transformed the passenger experience. After adopting CHIN NAN's customized RF connectors, Wi-Fi signal efficiency dramatically improved. At cruising altitudes of 30,000 feet, passengers could stream videos or attend business calls without frustration. Passenger complaints related to Wi-Fi dropped significantly, replaced by positive reviews of seamless connectivity.

For the client, CHIN NAN's solution wasn't just a connector upgrade—it was a total system reliability enhancement.

Need the right RF connectors for your aerospace communication system?

Contact our expert team today: service@chinnan.com.tw

From Innovation to Competitive Edge: Advancing In-Flight 5G

This collaboration resolved a key technical pain point while opening new business opportunities. Airlines gained reliable in-flight connectivity, improved customer satisfaction, and enhanced brand value. Meanwhile, our client strengthened its position as a preferred provider of airborne communication equipment, deepening relationships with aviation partners.

Whether for airborne communications, satellite systems, or other high-frequency wireless needs, CHIN NAN continues to lead with innovative RF connector technologies—empowering your next generation of reliable, high-performance connectivity solutions.

Looking for a wide range of RF connectors? Visit the CHIN NAN Online Store for easy browsing and quick ordering.

Want to explore more success stories? Check out other custom RF connector case studies across various industries.