Designing Industrial Connectors to Do More in Less Space

A high-level overview of connector trends, such as miniaturized, multifunctional connectors and modular plug-and-play designs.

Kristin McInnis

Related To:

HARTING, Inc of North America

Sept. 15, 2025

4 min read

Connector technology is changing in lockstep with the shrinking product envelope. Hybrid and modular connector formats carry power, signal and high-speed data in a single connector.

Industrial automation, robotics and edge devices are converging around a singular challenge: packing more capability into less space. As factories, medical instruments and autonomous systems become smarter and more connected, the pressure is on to shrink device footprints without sacrificing power, speed or reliability.

In today’s environment, every millimeter matters. Designers must address crowded control panels, densely packed printed circuit boards (PCBs) and rising connectivity demands—while end-users expect faster installs and easier maintenance. It’s no longer enough for a connector to simply fit; it must deliver the flexibility and multifunctionality underpinning the future of automation.

Whether in next-generation humanoid robots, compact control systems or lightweight motors, the ideal connector delivers power, signal and data in the tightest quarters, and supports predictive maintenance and sustainability initiatives. As innovation accelerates, connectors become both enablers and, if overlooked, bottlenecks for system design. The story of space-constrained connector technology is, at its heart, a story about doing more with less.

Harting PFT data panel feedthroughs — PFT data panel feedthroughs from Harting are designed to facilitate seamless connectivity for data cables.

Space-Constrained Design: How Connector Choices Define Possibility

Design for limited space shapes every stage of industrial product development. From packed control cabinets to the interiors of robotic arms, connector decisions impact system flexibility, upgradability and reliability. In fact, recent consultancy analysis highlights advances in connector miniaturization as key to scalability and competitiveness, making shrinking component footprints a true differentiator for leading OEMs.

Physical limits force engineers to make hard choices: balancing smaller connector size with performance and high-density layouts with strong signal integrity and ruggedness. Industry leaders deploy tight, high-density connectors, employ internal push-pull locking mechanisms and integrate multiple functionalities, such as power and data, with modular interfaces. These technical upgrades offer practical solutions to the urgent need for compactness.

But smaller size also brings new complexities: Tight layouts raise cross-talk and electromagnetic interference (EMI) risks, while maintenance and user safety remain non-negotiable in mission-critical settings. Today, the best connectors must offer secure latching, upgradable inserts for future-proofing and rapid installation—within the smallest possible footprint.

Innovations in Miniaturized, Multifunctional Connectors

Connector technology is redefining what’s possible within a shrinking product envelope. Modern connectors function as engineered interfaces, combining what once required multiple, bulky components, thanks to hybrid and modular formats capable of carrying power, signal and high-speed data in a single connector.

A standout advance is the rise of modular connector platforms. These allow engineers to mix and match inserts, optimize housing shapes and upgrade systems over time without full reconfiguration—enabling rapid iteration, reduced downtime and longer hardware lifecycles.

Push-pull locking and finer contact pitches further compress and expand connector capabilities. As industrial systems and edge devices continue shrinking, the role of the connector transforms from afterthought to agile, multifunctional platform central to system design.

Efficiency, Maintenance and What’s Ahead

Modern connectors streamline installation, cut maintenance, lower total cost of ownership and boost uptime. Migrating from labor-intensive hardwiring to modular connectors allows for faster swaps, simpler repairs and a reduction in errors. Connectorization can reduce install and service times by up to 40%, while simultaneously minimizing risk of miswiring and operational downtime.

These improvements optimize workflows but support sustainability by enabling upgrades and extending hardware’s useful life. Additionally, improved connectors ensure a connection that is secure, reliable and simple and efficient to make.

The reliance on connector technology will only intensify. As the backbone of tomorrow’s smart manufacturing, infrastructure and robotics, data must move through ever denser and more capable connectors. Modular plug-and-play designs support rapid evolution and new tech integration, without costly overhauls or extended downtime.

Connector innovation is central to enabling flexible, resilient and sustainable industrial growth. As the boundaries of what’s possible keep tightening—physically and technologically—the right connector decisions shape outcomes for reliability, sustainability and innovation across entire systems.

In a world defined by doing more with less, connector innovation isn’t just about space; it’s about building resilient, future-proof architectures that keep pace with the speed of change.