Electronic Contact Stamping
PrecisionElectronic Contact Stamping
Introduction to Electronic Contact Stamping Technology
Electronic contact stamping represents a critical manufacturing process in today’s interconnected world, producing the miniature metal components that power everything from household appliances to aerospace systems. As a professional metal stamping and deep drawing factory, ChinaMetalStamping specializes in delivering high-precision custom electronic contacts for global customers across multiple industries.
The electronic contact stamping process transforms raw metal materials into functional components through a combination of cutting-edge technology and engineering expertise. Our factory focuses on progressive die stamping – the most efficient method for producing high-volume, precision metal parts with consistent quality. This white paper explores our capabilities in manufacturing brass alloy electronic contacts with tin plating finish, while also detailing our comprehensive custom manufacturing services.
Sample Basic Parameters:
- Material: Brass alloy (C26000 standard)
- Thickness: 1.0mm ±0.05mm
- Dimensions: 21.0mm (L) × 6.0mm (W) ±0.1mm
- Surface Finish: Electroplated tin (3-5μm)
Important Notes:
- This sample serves as a reference for our manufacturing capabilities only.
- All specifications can be customized according to your technical requirements.
- Refer to the attached technical drawing (DWG/PDF format) for complete dimensional details.
Electronic Contact Materials
Brass Alloys: The Optimal Choice for Electrical Contacts
Brass alloys, particularly those in the copper-zinc family, have become the material of choice for electronic contact applications due to their unique combination of properties:
- Superior Electrical Conductivity: With typical conductivity ranging from 28% to 45% IACS (International Annealed Copper Standard), brass provides excellent current-carrying capacity
- Enhanced Mechanical Properties: The zinc content in brass alloys improves hardness and wear resistance compared to pure copper
- Cost-Effectiveness: Brass offers nearly 80% of copper’s conductivity at approximately 60% of the material cost
- Formability Characteristics: Excellent for complex stamping operations including bending and deep drawing
Material Specifications for Electronic Contacts
At ChinaMetalStamping, we work with various brass alloys to meet specific application requirements:
| Alloy Designation | Copper Content | Zinc Content | Key Characteristics |
|---|---|---|---|
| C26000 (Cartridge Brass) | 70% | 30% | Excellent balance of strength and formability |
| C27200 (Yellow Brass) | 67% | 33% | Higher corrosion resistance |
| C22000 (Commercial Bronze) | 90% | 10% | Maximum conductivity |
For the sample specification provided (1mm thickness, 21mm × 6mm dimensions), we typically recommend C26000 brass due to its optimal performance in progressive die stamping applications.
Progressive Die Stamping: Our Core Manufacturing Process
The Progressive Die Stamping Advantage
Progressive die stamping stands as the most efficient manufacturing method for high-volume electronic contact production. This automated process offers several distinct advantages:
- Precision Engineering: Capable of maintaining tolerances as tight as ±0.01mm
- High-Speed Production: Our presses can produce up to 1,200 parts per minute
- Material Efficiency: Nesting optimization minimizes scrap loss
- Consistent Quality: Automated production ensures part-to-part uniformity
Our Progressive Die Stamping Workflow
- Material Feeding: Coiled brass strip automatically feeds into the stamping press
- Pilot Piercing: Creates registration holes for precise material positioning
- Blank Punching: Rough-cuts the contact outline
- Forming Stations: Progressively bends and shapes the contact
- Final Trimming: Completes the precise perimeter cut
- Ejection: Finished parts automatically separated from the carrier strip
For the 21mm × 6mm contact sample, we would typically design a 6-8 station progressive die to ensure optimal quality and production efficiency.
Surface Finishing: Tin Plating Process Details
Why Tin Plating for Electronic Contacts?
Tin plating serves as one of the most common and effective surface treatments for brass electronic contacts due to:
- Superior Solderability: Enables reliable PCB attachment
- Oxidation Resistance: Protects the base material from corrosion
- Cost Efficiency: More economical than gold or silver plating
- Low Contact Resistance: Maintains excellent electrical performance
Our Tin Plating Process Specifications
| Parameter | Specification |
|---|---|
| Plating Method | Electroplating |
| Tin Thickness | 3-5μm (adjustable per requirement) |
| Underlayer | Optional nickel barrier (for enhanced durability) |
| Post-Treatment | Passivation (improves shelf life) |
| Quality Standards | ASTM B545, ISO 4523 |
The matte tin finish we apply provides optimal performance for most electronic contact applications while maintaining cost-effectiveness for volume production.
Custom Manufacturing Capabilities
Comprehensive Material Options
While brass represents our most common material for electronic contacts, we support full customization across:
- Copper Alloys: Phosphor bronze, beryllium copper
- Nickel Alloys: Nickel silver, nickel-copper
- Stainless Steels: 301, 304, 316 for specialized applications
- Exotic Materials: Kovar, Inconel for extreme environments
Dimensional Flexibility
Our capabilities extend far beyond the sample specification (1mm thickness, 21mm × 6mm):
- Thickness Range: 0.1mm to 5.0mm
- Length/Width: From 0.5mm micro-contacts to 150mm large terminals
- Tolerance Capability: ±0.005mm for critical dimensions
Surface Treatment Alternatives
In addition to standard tin plating, we offer:
- Precious Metal Plating:
- Gold plating (0.05-5μm thickness)
- Silver plating (3-8μm thickness)
- Palladium-nickel alloys
- Specialty Finishes:
- Selective plating (contact areas only)
- Immersion coatings
- Conductive lubricants
- Anti-Corrosion Treatments:
- Chromate conversion
- Organic coatings
- Passivation processes
Quality Assurance and Testing Protocols
In-Process Quality Controls
- First Article Inspection: Complete dimensional verification of initial production samples
- Statistical Process Control: Real-time monitoring of critical parameters
- Tooling Maintenance: Scheduled die maintenance to ensure consistency
Final Product Testing
| Test Category | Methods | Equipment | Standards |
|---|---|---|---|
| Dimensional | Optical comparator, CMM | Mitutoyo CMM | ISO 2768 |
| Plating Thickness | X-ray fluorescence | Fischer XDV-SDD | ASTM B568 |
| Conductivity | 4-point probe | Signatone S-302 | ASTM B193 |
| Solderability | Wetting balance | METRONEL UTM | IPC J-STD-002 |
| Mechanical | Microhardness tester | Wilson Tukon | ASTM E384 |
Certifications and Compliance
- ISO 9001:2015 Quality Management System
- IATF 16949 for automotive components
- RoHS and REACH compliance documentation
- UL recognition for relevant components
Industry Applications and Case Studies
Electronics Manufacturing
Our electronic contacts serve critical functions in:
- Connector Systems: PCB headers, socket contacts
- Switchgear: Relay contacts, breaker components
- Consumer Electronics: SIM card connectors, battery contacts
Case Example: Produced 15 million smartphone SIM tray contacts with 5μm gold plating, maintaining ±0.02mm positional tolerance for a major mobile device manufacturer.
Automotive Electronics
- Sensor Components: ABS, TPMS, oxygen sensors
- Power Distribution: Fuse box components
- Lighting Systems: LED connector contacts
Case Example: Developed beryllium copper spring contacts for electric vehicle charging ports with 100,000+ mating cycle durability.
Industrial and Medical Applications
- Control Systems: Industrial relay contacts
- Medical Devices: ECG electrode components
- Aerospace: Avionics connector systems
The ChinaMetalStamping Advantage
Technical Expertise
- 20+ years specializing in precision metal stamping
- Engineering team with 50+ combined years of experience
- Proprietary die design and simulation software
Manufacturing Capabilities
| Facility Feature | Specification |
|---|---|
| Press Capacity | 5-300 tons |
| Production Speed | Up to 1,200 SPM |
| Precision Level | ±0.005mm |
| Maximum Strip Width | 250mm |
| Material Handling | Automated coil feeding |
Customer-Centric Services
- Design Support: DFM analysis and optimization
- Prototyping: Rapid tooling for sample development
- Logistics: JIT delivery programs
- Inventory Management: Consignment stock options
Conclusion: Your Trusted Electronic Contact Stamping Partner
ChinaMetalStamping combines advanced manufacturing technology with deep materials expertise to deliver precision electronic contacts that meet the most demanding specifications. From the sample brass contact with tin plating (1mm thickness, 21mm × 6mm) to complex multi-material assemblies, we provide complete custom stamping solutions.
Our progressive die stamping process ensures consistent, high-volume production while maintaining tight tolerances and excellent surface finishes. With comprehensive in-house capabilities spanning material selection, tooling design, precision stamping, and surface treatment, we serve as a single-source solution for global electronics manufacturers.
