Connector Manufacturing Production Process

Analysis of various types of connector manufacturing procedure and technique, both theoretical and practical, during the connector manufacturing procedure and design phase; however, there are many types of connector analysis during the production and design phases. However, the production process is essentially the same throughout. The various types of connector production process include; EDM (electro-mechanical data), ribbon, wafer, flexible, metal, plated, silver, and gold-filled wire or cable. Several manufacturing techniques are used to create each type of connector, such as cold-forming, hot-forming, roll-forming, wire crimping, wire folding, etc. In addition, a variety of materials is utilized for the various types of connectors, including; steel, fiberglass, glass, rubber, nylon, polyester, plated, and other manufactured fiber or metal products.

The majority of the connector manufacturing technologies are initiated at the connector manufacturing facility and are performed through equipment operated by trained personnel or automated machinery. A large part of the connector manufacturing operations can be completed on-site; however, in some cases, the bulk of the work can be done by utilizing off-site processing equipment and other technologies. For example, when large-scale cable assembly is required, the entire process can be completed off-site, where large equipment such as CNC machines or automated die-making machines are utilized. Additionally, some manufacturers require that the complete design be sent either through an electronic format or paper file. This allows the manufacturer to review the design and any pertinent documents related to the production.

As stated before, most connector manufacturing productions will utilize on-site processing equipment, such as CNC machines and automated die-making machines. However, in some instances, such as short-run output or small quantity productions, it may be necessary to utilize off-site tools and processes to meet production process parameters. For this reason, many connector manufacturers will provide training sessions for all employees before each new batch of products is turned out. In addition, many manufacturers will take issue with poor artistry and quality in their products. Therefore, they will work with customers to ensure that all produced products are of the highest possible quality.

The majority of connector production inspections take place within the factory where the finished product is located. However, as is always the case when dealing with highly complex and sophisticated products, it is sometimes necessary to transport the completed units to different sites across the country or around the world. Some manufacturers are global and have employees operating from their facilities stationed in various shipping locations around the globe. Regardless of whether an assembly is completed in the factory or on a pallet transported overseas, there will usually be an inspection phase completed before the pins can be sold.

This inspection system is used to ensure that the pins are correctly connected; it is also used to test the assembly to make sure that the quality of the product meets the expectations of both the customer and the manufacturer. Many companies will employ several different testing methods, including pin-to-stamp contact testing, double-sided tape testing, moisture plug testing, etc. Some connectors are produced by using a solid flux-cored hole spacer that is installed between the mating pins. Other companies use a metallic flux-cored hole spacer that has no flux holes.

Connector manufacturing requires that these products be examined regularly to ensure no excessive levels of friction occur due to extreme heat, deformation, etc. Therefore, many companies employ a high-tech electroplating inspection program to test and analyze their connector pins. Electroplating is a manufacturing method that involves using a high resistance electric current to apply a very thin layer of indium tined coating to various metals. Once the coating is applied to the connector pins, the metal is rapidly charged with an electrical current. It is then exposed to an ionic bath where various impurities are bonded to the metal by infusing them into the pores of the metal coatings. This allows the layer to be peeled away, quickly inspected, and tested.

The manufacturing processes that take place in this industry are exact. The entire production process from the initial blueprint to the finished product can take up to three weeks. Each batch can last up to three weeks, and the whole process must occur with great precision to reduce waste and errors. In addition, every connector that leaves the plant must pass through numerous quality control checks to ensure that they meet the manufacturers’ quality standards and customers’ needs.

The production process parameters are continuously monitored to ensure that every item produced meets stringent standards and is made at a consistent rate. The entire process of connector manufacturing can be divided into four primary steps: design development, material development, component manufacturing, and final inspection and testing. The design development process involves conceptualizing and designing each component that will go into the final product. Material development involves researching materials that will best suit the intended application. Finally, component manufacturing involves production and packaging processes.