Electrical Connector Accessories & Assembly Tools
Hyperboloid Contacts (Double-curved contact design)
- Structural Design: Uses multiple gold- or silver-plated flexible metal wires arranged in a single-helix hyperboloid shape. The wires are positioned at an angle to the inner sleeve axis. When the pin is inserted, the wires deform both radially and axially, creating multiple independent current paths. Even if one wire breaks, electrical conduction is still maintained.
- Main Advantages: Low and stable contact resistance, low insertion force, minimal wear, and long service life. In strong vibration or shock environments, the momentary interruption is less than 1 μs, ensuring very high reliability and resistance to failure.
- Typical Applications: Aerospace systems, defense equipment, oil exploration tools, and medical devices where very high reliability is required.
Twist Pin Contacts (Twisted pin contact design)
- Structural Design: Made using a twisted wire structure combining “3 inner pure copper strands + 7 outer beryllium copper strands”. The design creates a contact diameter larger than the mating hole, forming a stable multi-point contact. A crimped rear structure ensures mechanical strength with tensile resistance of ≥30N.
- Main Advantages: High elasticity and strong resistance to vibration and shock (up to 150g acceleration and 3000 cycles). Smooth insertion and stable performance even after 1000 mating cycles, with almost no change in contact resistance or insertion force. Works with both rigid and flexible contact sockets.
- Typical Applications: Automotive electronic testing, railway systems, smart devices, and general industrial connector applications.
We provide a full range of standardized contact solutions for major military and industrial connector series, fully compatible with commonly used industry standards:
| Series | Standards Compliance | Application | Feature |
| MIL-DTL-38999 | Mil-Spec Circular Connector | Aerospace, Defense, Marine Systems | High-vibration , hermetic sealing, corrosion resistant, high-speed/high-current capability |
| MIL-DTL-26482 | Mil-Spec Miniature Circular | Airborne, Tactical Radio | Minimized size, high reliability, high-density signal integration |
| M80 / HWC | British-Spec, Industrial Military Standard | Railway, Industrial, Test | High precision, extended mating cycles, modular/standardized interface adaptability |
Besides the standard connector series, we support full-process custom development of electrical contacts for industrial and military connectors. Customized connector solutions can be developed based on customer samples, drawings, or technical parameters such as current and voltage ratings, contact resistance, insertion force range, plating materials, and dimensional tolerances.
Customization Capabilities- Material options: Base materials include copper alloys and beryllium copper, with optional plating such as gold, silver, or palladium-nickel coatings.
- Structural design: Contact types include hyperboloid, twist pin, and crown spring designs. Different terminal sizes and mounting methods are available, such as crimping, soldering, or PCB installation, depending on the application.
- Performance optimization: Parameters such as vibration resistance level, operating temperature range, mating cycles, and environmental protection (salt spray, humidity, corrosion) can be optimized according to specific requirements.
Delivery Support
We offer full support, from design and prototyping through to mass production, with final products tested and certified according to application requirements.