Wire-forming Technology for Connector Pins

Our unique wire-forming technology – precise, reliable and cost-effective

Connector pins are commonly manufactured with stamping presses. Using sophisticated, progressive die-stamping tools, a high level of precision and quality can be achieved. For large production quantities and standard components, traditional stamping is the technology of choice, also from a cost perspective. Due to the high initial costs, creating a customized pin for small- to medium-sized production volumes can be prohibitive. The design flexibility is also very limited once a custom tool has been created. This is where our wire-forming technology comes in, allowing the manufacture of customized contact pins without tooling charges and with a high degree of flexibility.

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About the product

About the sector

bandolier precision connector pins

Our process: Combining customization with series production

Our process starts with very precise round or square wire, which is supplied on a spool. All common contact pin materials that are available as a wire can be used (commonly, brass, bronze and other copper-based alloys are employed). After feeding and straightening the wire, our equipment employs a series of swaging units (pyramidal stamping units) to create the specified pin features. The resulting design features are virtually scrape-less, as no material is removed during the cold-forming process. The swaging units can be easily exchanged and customized to offer a high degree of design flexibility. Camera systems for 100% optical inspection are then used for process control where required.

As an alternative to swaging, pin ends can be formed by thermal restriction. In this process, the wire is clamped from two sides. A strong electrical current then heats the wire up while it is mechanically pulled apart. This results in extremely smooth pin ends that are completely scrape-less and free of burs.

Three different packaging variants exist for wire-based contact pins: Single, bandolier and end-to-end.

Single pins (solid wire pins) are completely separated and supplied loosely in a package. Angled pin geometries can be created in post-processing steps. Usually, these pins are fully plated, although the possibility of selective plating exists.

Bandolier pins are put onto a bandolier after separation. Depending on the equipment, the pins can be inserted in an axial or radial direction. The insertion into the bandolier is 100% controlled by camera systems. Usually, these pins are selectively plated before going to our customers.

End-to-end pins (continuous wire pins) are not completely separated and are supplied on continuous reels. The separation of the pins is performed by the pin-insertion machine at the assembly site. All end-to-end pins are manufactured with pre-plated wire.

Our Products and Services

The Dietze Group helps its customers with custom interconnection solutions from concept to series production. Our products are designed in close collaboration with our customers and engineered to meet the application’s specific needs.

Glass-to-Metal Seals

Glass-to-metal feedthroughs provide electrical connections into hermetic packages, even under extreme conditions.

Connector Pins & Stamping

High-precision terminal pins and stamping parts guarantee reliable electrical connections in demanding applications.

Lead-in Wires

Welded leadwires provide the interconnection for light sources and special-purpose electronic applications.