Custom Electrical Connector Terminals
Richconn manufactures custom electrical connector terminals from prototype to millions of pieces per month. Our 340+ CNC machines — including Citizen Swiss-type lathes, Mazak turn-mill centers, and Star core-walking machines — deliver tolerances to ±0.005 mm across brass, copper, stainless steel, and specialty alloys. IATF 16949 and AS9100D certified for automotive and aerospace connector applications.
CNC Machines
Tolerance
Years Exp
Types of Custom Connector Terminals We Manufacture
From micro-diameter pogo pins to high-current EV charging terminals, Richconn machines every type of electrical connector terminal used in modern electronics, automotive, industrial, and aerospace systems.
Pogo Pin / Spring-Loaded Contact
Male / Female Terminal Pin
Pin / Socket Contact
RF Connector Center Pin
SMA/SMP/MMCX Contact
D-Sub Connector Pin
Board-to-Board Connector Terminal
Pin Header / Female Header
FPC/FFC Connector Contact
Type-C Inner Terminal
Lightning Connector Pin
Micro USB Terminal
Materials for Custom Connector Terminals
Selecting the right material is critical for electrical conductivity, mechanical durability, and corrosion resistance of connector terminals. Richconn processes over 15 alloy families with full RoHS traceability from mill certificate to finished part.
| Material | Grades | Typical Application | Key Properties |
|---|---|---|---|
| Free-Cutting Brass | C3604 · C3602 · CuZn37Mn3Al2PbSi | General-purpose connector pins, RF contacts, pogo pin barrels | Excellent machinability, good conductivity (26% IACS) |
| Pure Copper | C1100 · C1020 (OFHC) | High-current EV charging terminals, busbar connectors | Highest conductivity (100% IACS), soft, requires support tooling |
| Phosphor Bronze | C5191 · C5210 | Spring contacts, FPC connectors, socket terminals | High fatigue strength, excellent spring properties, 15% IACS |
| Beryllium Copper | C17200 · C17500 | High-reliability aerospace contacts, test probe tips | Highest strength copper alloy, 22% IACS, non-sparking |
| Stainless Steel | 303 · 304(L) · 316(L) · 410 · 440C | Sensor housings, connector shells, harsh-environment contacts | Corrosion resistance, high strength, magnetic options (400 series) |
| Aluminum Alloy | 6061-T6 · 7075-T6 · 2024-T351 | Connector housings, backshells, EMI shielding enclosures | Lightweight, excellent machinability, anodizable |
| Titanium | Ti-6Al-4V (Grade 5) | Aerospace connector contacts, medical device connectors | Highest strength-to-weight, biocompatible, corrosion-proof |
| Nickel Superalloy | Inconel 625 · Inconel 718 | High-temperature aerospace connectors, exhaust sensor probes | Service to 700°C, extreme corrosion resistance |
CNC Equipment for Connector Terminal Production
Our equipment ranges from micro-diameter Swiss-type lathes for pogo pins to 5-axis machining centers for complex connector housings.
Swiss-Type Turn-Mill Centers
Φ0.5–Φ120 mm capacity. Simultaneous turning, milling, drilling, and threading in a single setup. Ideal for complex pogo pin barrels, RF center pins, and multi-feature automotive terminals at ±0.005 mm.
Swiss-Type CNC Lathes
Φ0.5–Φ20 mm. Dedicated high-speed Swiss machines for micro-diameter connector pins, socket contacts, and board-to-board terminal pins at production speeds exceeding 2,000 pcs/hour.
Automatic Lathes
Φ1–Φ15 mm. The workhorse for ultra-high-volume simple-geometry connector pins, standoffs, and rivet-type terminals. Capable of millions of pieces per month with sub-¥0.1 unit costs.
CNC Machining Centers
3-axis, 4-axis, and 5-axis vertical and horizontal machining centers for connector housings, backshells, manifold blocks, and complex multi-cavity connector bodies.
CNC Rotary Indexers
96 rotary indexers including 4 five-axis units. Enables multi-face machining of complex connector shells and housings in a single clamping, eliminating repositioning error.
Mazak Turn-Mill Compound Centers
Combined turning and milling in one machine for connector components requiring both rotational and prismatic features — such as flanged terminal bodies and threaded connector adapters.
Plating and Finishing for Connector Terminals
Surface finish directly affects contact resistance, corrosion life, and solderability of connector terminals. Richconn offers a comprehensive range of plating and finishing processes through in-house EP lines and qualified plating partners.
Gold Plating
Hard gold (Au-Co) for high-reliability contacts; gold flash for cost-sensitive applications. Thickness from 0.05 µm flash to 1.27 µm full gold per MIL-DTL-45204. Delivers lowest contact resistance and best corrosion protection for signal-level connectors.
Nickel Plating
Electroless nickel (EN) and electrolytic nickel for wear resistance and as a barrier layer under gold. Richconn partners operate dedicated EN plating lines producing uniform Ni-P deposits with hardness up to 700 HV after heat treatment.
Tin & Silver Plating
Matte tin for RoHS-compliant solderability on PCB terminals. Silver plating for high-current EV charging contacts — delivers 106% IACS conductivity at the contact interface. Both available in selective plating configurations.
Electropolishing (EP)
In-house electropolishing line produces Ra < 0.25 µm mirror surfaces on stainless steel and titanium connector components. Essential for semiconductor-grade and medical-grade connector contacts requiring ultra-clean surface finishes.
Passivation & Anodizing
Citric acid and nitric acid passivation for stainless steel per ASTM A967. Type II and Type III hard anodizing for aluminum connector housings and backshells providing dielectric isolation and wear resistance.
Heat Treatment
Age hardening for beryllium copper contacts (C17200) to achieve peak spring properties. Stress relief for phosphor bronze terminals. Vacuum heat treatment available for aerospace-grade titanium and Inconel components.
Connector Terminal Production Process
From your CAD drawing to packaged parts, Richconn follows a structured DFM-driven production process with inspection gates at every stage.
DFM Review
Engineering assessment of your drawing. Tolerance, material, and process recommendations within 24 hours.
Prototyping
First articles in 5–7 business days. CMM inspection report (FAI) included with every prototype shipment.
PPAP / Sample Approval
Full PPAP documentation per IATF 16949 for automotive customers. Dimensional report, material cert, and process flow diagram.
Mass Production
CNC machining with SPC monitoring. IQC → IPQC → FQC → OQC four-stage quality gates. CCD auto-sorting for critical dimensions.
Surface Treatment
Plating, passivation, heat treatment, or electropolishing per your specification. Salt spray and thickness verified post-process.
Delivery
Vacuum-sealed anti-oxidation packaging. Reel, tube, tray, or bulk pack options. Global shipping with lot traceability.
Where Our Custom Connector Terminals Are Used
Richconn connector terminals are deployed across industries demanding high reliability, high volume, and tight tolerances
Consumer Electronics
- Smartphone charging contacts
- TWS earphone pogo pins
- Smartwatch magnetic connectors
- Laptop Type-C inner terminals
- Camera module contacts
Automotive & EV
- Wire harness terminals
- EV charging gun contacts
- HV battery pack pins
- ECU connector pins
- ABS/ESP sensor terminals
Telecom & 5G
- SMA/SMP RF center pins
- Base station antenna feeds
- Optical transceiver contacts
- Server backplane pins
- Coaxial cable connectors
Aerospace & Defense
- MIL-SPEC circular contacts
- Avionics connector pins
- Hermetic feedthrough terminals
- Satellite RF interconnects
- Flight control harness pins
Semiconductor Equipment
- Test probe pins
- IC test socket contacts
- Wafer prober needles
- Burn-in socket pins
- Handler contact probes
Medical Devices
- Endoscope signal contacts
- Patient monitor connectors
- Implantable device feedthroughs
- Surgical robot interface pins
- IVD instrument probe tips
Industrial Automation
- Servo drive connector pins
- PLC I/O terminal contacts
- Sensor connector terminals
- Heavy-duty power contacts
- Robot teach pendant pins
Energy & Power
- Battery PACK interconnect pins
- Inverter busbar terminals
- Solar junction box contacts
- EV charger pile terminals
- DC contactor contacts
How We Ensure Connector Terminal Quality
With IATF 16949 and AS9100D dual certification, Richconn applies automotive and aerospace-grade quality control to every connector terminal we produce. Our inspection equipment includes Mitutoyo CMM, CCD auto-sorting machines, and industry-specific testers.
CMM & OMM Inspection
Mitutoyo coordinate measuring machine (±0.001 mm) for first article inspection and SPC dimensional monitoring. On-machine measurement (OMM) for in-process verification without removing parts.
CCD Auto-Sorting
Vision-based automatic sorting machines inspect 100% of production output at speeds up to 600 pcs/min. Detects dimensional deviations, surface defects, and plating irregularities — critical for pogo pins and micro-contacts.
Insertion Force Testing
Push-pull force testers (0–50 kg, ±0.05 accuracy) verify insertion and extraction force per connector OEM specifications. Essential for automotive terminals complying with USCAR and LV 214 standards.
2D / 2.5D Optical Measurement
Profile projectors and video measuring systems for non-contact measurement of delicate connector pins. 4 projectors and 4 video measurement machines ensure no inspection bottleneck in high-volume production.
Salt Spray & Environmental Testing
Salt spray testing per ASTM B117 verifies plating corrosion resistance — typically 48–96 hours for automotive terminals, up to 500 hours for aerospace contacts. RoHS XRF analysis confirms material compliance.
Surface Roughness & Hardness
Mitutoyo surface roughness tester (Ra measurement) and Vickers hardness tester verify post-machining and post-heat-treatment properties. Critical for spring-loaded contacts requiring specific hardness ranges.
Ready to Start Your Connector Terminal Project?
Send Richconn your drawing, material requirement, annual volume, and any plating or inspection requirements. We can review the part structure, evaluate the machining route, and provide a practical quotation for prototype or production supply.