Stamped contacts served RF connectors in telecom equipment, requiring consistent spring force and electrical contact.
The customer’s challenge
Variable spring force, high contact resistance, short insertion life and plating loss affected connector performance.
Material and fabrication route
0.2 mm C5191 phosphor bronze; gold plating.
Process route: Tool design → stamping → heat treatment → gold plating → spring-force testing → resistance testing.
Manufacturing changes
Revised tooling and heat treatment controlled hardness to HV180–210. Controlled plating thickness and complete spring-force sorting improved consistency.
Engineering analysis
The contact needed consistent spring behavior and a stable electrical surface over repeated insertion. Tooling and heat treatment addressed force, while plating control and sorting addressed the supplied contact condition. Force tolerance, resistance and cycle life describe different acceptance checks. The monthly quantity indicates production scale but does not replace the part-level electrical and mechanical criteria needed for a repeat order.
Inspection and project results
Contacts reached the stated force tolerance, resistance and insertion-cycle results without observed plating loss.
| Project measurement or production detail | Recorded value |
|---|---|
| Spring-force tolerance | ±10% |
| Contact resistance | ≤20 mΩ |
| Insertion test | ≥10,000 cycles |
| Gold thickness | ≥0.5 μm |
| Production quantity | 100,000 parts/month |
These figures describe the project configuration and production scope above. Dimensional, material and production details are identified separately from performance tests. For a new order, the inspection method and acceptance criteria should be agreed against the released drawings.
Planning a similar OEM component
A useful RFQ for this application should make the following interfaces and acceptance requirements clear:
- Contact geometry and mating travel.
- Spring-force window.
- Plating stack and thickness.
- Resistance and insertion-cycle acceptance.
Include the current drawing revision, mating-component information, quantities and required delivery sequence. Identifying unresolved requirements at quotation stage helps distinguish fabrication work from the equipment-level checks that the project needs.
For related manufacturing support, review our Phosphor Bronze Stampings and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
