2024-11-14

How Are Electronic Connectors Made?

Our world is slowly becoming a digital-only environment. It's nearly impossible for most people not to run into technology assisting our daily routines, such as train depots, restaurants, hospitals, remote working, and automobiles. However, for all of these different support systems to work, we must incorporate electronic connectors into our lives. These standardized or customized connectors allow our society to evolve and prevent normally impossible tasks from impeding our lives. But, despite this much-needed technology, how these components are made is still a mystery to many. To prevent any misunderstandings, Oupiin Group has created an easy-to-read article for you, your colleagues, friends, and family.

Normal Connector Creation Process

Fortunately, the creation of electronic connectors has been standardized across various countries, industries, and associations. Yes, manufacturers have to comply with various certifications, such as the IATF 16949 , ISO 13485 , ISO 14001-KS , and many more. But, the normal creation approach for electronic connectors can be summarized into a 7-step process:

The Specifications Stage
The Design Stage
The Prototyping Stage
The Mass Production Stage
The Quality Control Stage
The Packaging Stage
The Feedback Stage

The Specifications Stage

Before any selling or creating can be performed, the manufacturer needs to pinpoint the exact requirements the connector will involve. For instance, engineers need to identify what kind of electronic connector it is, such as a board-to-board (BTB) connector, wire-to-board connector, high-speed card edge connector, backplane connector, D_Sub connector, automotive connector, USB connector, FFC/FPC connector, SFP, SFP+ & QSFP+ connectors, terminal block, cable assembly, and many more. Following this , the creator will have to decide on electrical specifications (voltage, currents, and signal integrity), mechanical constraints (housing, size, shape, and mounting options), material selection (copper, gold, nickel, and plastic), and environmental considerations (temperature, humidity, and exposure to chemicals). Once all of this is identified, the design stage can proceed.

The Design Stage

The previous stage's specifications will allow engineers to brainstorm and develop connector blueprints. These can include evaluating the feasibility of the part, the manufacturability, how much it will cost to create the whole electronic connector, and whether these specifications will comply with industry standards and regulations . How is all of this imagined? Computer-aided design (CAD) software provides these creators with a visual representation of what these connectors look like, how they will function, and how effective they will be in their duties. These details can even be represented in a 2D or 3D format for maximum proficiency. These resources and support systems allow manufacturers to emphasize the success rate of said connector without wasting money constantly developing new parts that may malfunction or not satisfy compliance rules. Because of these specifications, the prototyping phase will be quicker to initiate and more likely to lead to success.

The Prototyping Stage

The Prototyping Stage requires the most attention since this step prevents complications from disrupting the client's own manufacturing and creation process. Using the designs made in the previous steps and 2D/3D visualizations, electronic connector manufacturers can create a prototype matching the chosen details and mandatory regulations . Once the prototype connector is created, the component will undergo comprehensive testing to examine electrical, mechanical, and environmental performances. These can include:

Environmental evaluation and resistance to extreme temperatures, humidity, and vibration
Measuring impedance
Prevention of excessive insertion loss
The avoidance of crosstalk
Durability testing
Insight into insertion and removal forces
Identifying mating cycle limits
Conductivity
Mechanical strength

These tests will repeatedly occur until the prototype connector is refined enough to satisfy performance, reliability, and manufacturability demands. The process's timeline can vary between a few weeks to a few months. It ultimately depends on the manufacturer's attention to detail, efficiency, and needed materials since most brands want to guarantee you obtain an electronic connector that is durable, effective, and powerful. To prevent working with an outdated electronic connector manufacturer, consider asking for connector datasheets, certificate tests, public client testimonials, and the materials they use to create their products. Nonetheless, after all of this testing and refining is finished, the next stage proceeds.

The Mass Production Stage

While the prototype connector may have been determined and was successful during the foundational tests, the tools needed to produce these electronic connectors on a mass scale have to be created. These can include fixtures, jigs, and injection molding for plastic connectors or dyes for stamping metal connectors. Metal connectors will also need tools configured for machining and casting treatments. Thankfully, most, if not all, of this work is automated, which means inserting contacts, attaching housings, and sealing components can be done quickly and efficiently.

The Quality Control Stage

While the Prototyping Stage utilized various tests to ensure success for the connector, this stage verifies the previous results, as well as guarantees quality is met. Mass production can cause some irregularities to appear, which is why this stage is incredibly crucial for the fabrication of large-scale electronic connector manufacturing. These quality control inspections and testing procedures will affirm dimensional accuracy, material properties, electrical conductivity, and overall performance. These examinations may use one of many techniques, such as statistical process control (SPC) to monitor and maintain production quality. Once everything is confirmed to work well, if not better, than predicted, then these mass-produced connectors can be packaged and shipped off to their new homes.

The Packaging Stage

The first step of this stage involves the final assembly of the connector so it's prim and proper for the client. Although, depending on the receiver and industry standards, the packaging may be different for each electronic connector. Some clients will want extra protection, some businesses may want the basics. But, the consumer can rest easy knowing it will have all of the appropriate labeling, instructions, and certificates. However, were the customer to have any questions, compliments, or complaints, they can dutifully engage in the next stage.

The Feedback Stage

Every electronic connector manufacturer is different when it comes to how they handle the creation, delivery, and support of their clients' needs. For example, Oupiin Group will continue to provide support, technical assistance, and product updates to the client's order even after the connector is delivered. Not only does this ensure the client is satisfied with the products, but it also allows us (Oupiin Group) to conceptualize improved future designs and product enhancements. Your feedback is important and it can't be stated enough how much electronic

connector manufacturers rely on this stage.

Contact Oupin Group Today!

Throughout this electronic connector creation process, collaboration between design, engineering, manufacturing, and quality assurance teams is essential for the successful development and production of electronic connectors. These standards rigid for quality ensures these connectors meet the client's required specifications, level of quality, and reliability standards. However, if a truly unique and original electronic connector is being requested, modular tooling should be considered . Regardless of this niche service, electronic connector manufacturers, like Oupiin Group, are continuously improving on electronic connectors' materials, costs, features, and sustainability.

However, if you have any questions or concerns about our electronic connector creation methods, we'd love to satisfy your curiosity. You can send an email to sales@oupiin.com or call us at one of our international locations. 1(661) 294-0228 for the California, United States of America, location, or +886-3-3655030 for the Taoyuan, Taiwan, location or send an email to sales@oupiin.com.tw . We are here to help and serve; reach out to us as soon as you are ready.