Project Overview
A connector manufacturer required precision housings for electrical connectors. The project demanded precise pin alignment, secure locking, and high-volume production.
Challenge
- Pin Alignment: ±0.05mm tolerance
- Secure Locking: Reliable connection
- Electrical Continuity: Proper conductor seating
- Volume: 5M+ units
- Cost: Competitive for electronics market
Solution
Precision Manufacturing
- High-precision tooling
- Tight process control
- Automated pin insertion
- Locking mechanism verification
Quality Systems
- CMM verification on pin locations
- Mating force testing
- Electrical continuity testing
- 100% automated inspection
Results
| Metric | Target | Achieved |
|---|---|---|
| Pin Alignment | ±0.1mm | ±0.05mm |
| Mating Issues | <500 PPM | 0 PPM |
| Units Delivered | 5M | 10M+ |
| Continuity Pass | 99.9% | 100% |
| Field Failures | <50 PPM | 0 PPM |
Customer Testimonial
“CoreLMould’s connector housings are precision-perfect. ±0.05mm pin alignment, zero mating issues, and 10M+ units flawlessly. Outstanding electronics partner.”
- Engineering Director, Connector Manufacturer