Precision stamping, injection molding, automated assembly, and in-house quality testing.
High-speed progressive die stamping for connector contacts and terminals. Our presses operate at up to 1,200 strokes per minute with positional accuracy of ±0.01mm. Materials processed include phosphor bronze (C5191), brass (C2680), and beryllium copper (C1720).
Capacity: 60M+ contacts/month | Tolerance: ±0.01mmMulti-cavity molds for connector housings and insulators. 28 injection molding machines ranging from 30-ton to 180-ton clamping force. Engineering-grade resins: PA6T (Nylon 6T), PBT, LCP, and PPS for high-temperature applications up to 260°C reflow.
Machines: 28 units | Shot weight: 0.5g to 120gRobotic contact insertion and housing assembly lines with in-line vision inspection. Each assembly station checks contact alignment, retention force, and housing integrity before passing to electrical test. Cycle time: 0.8 seconds per connector.
Lines: 3 automated | Cycle: 0.8 sec/unitIn-house testing for contact resistance (four-wire Kelvin method), insulation resistance (500V DC megohmmeter), dielectric withstand (1,000V AC for 60 seconds), and environmental cycling (-40°C to +125°C, 1,000 cycles). Salt spray testing per ASTM B117 for plating durability.
Tests: Electrical + Environmental + MechanicalIn-house tool room with wire EDM, CNC milling, and surface grinding for progressive dies and injection molds. Custom tooling lead time: 15-20 business days. Mold life: 1M+ shots for standard resins, 500K+ for glass-filled materials.
Lead time: 15-20 days | Mold life: 1M+ shotsSelective gold plating (0.2-0.8μm Au over 1.0-2.5μm Ni) for signal contacts, tin plating for power contacts, and nickel barrier layers. Plating thickness monitored by XRF fluorescence analysis on every production lot.
Gold: 0.2-0.8μm | Tin: 1.0-3.0μm | Nickel: 1.0-2.5μmOur standard production covers pitches from 1.0mm (SH series) to 3.96mm (VH series). Connectors below 0.8mm pitch or above 5.08mm pitch require custom tooling evaluation, and lead times extend to 25-35 business days due to tighter die tolerances.
Maximum continuous current per contact is 10A (VH series at 20°C ambient). Applications requiring above 15A per contact path should consider dedicated power connectors from specialized manufacturers. Derating applies above 60°C ambient: reduce rated current by 2% per degree.
Standard connector housings (PA6T, PBT) are rated for continuous operation up to +105°C. High-temperature applications above +150°C require LCP housings, which are available only for XH and GH series with minimum order quantities of 10,000 units. Outdoor installations require IP67-rated variants with silicone gaskets, adding 15-20% to unit cost.
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