Other items for harnesses

1. Design & Engineering

• Engineers design connectors based on automotive industry requirements (e.g., voltage, current rating, environmental resistance).

• Prototypes are developed using CAD software and undergo simulation testing.

• Materials (plastics for housings, metals for terminals) are selected for durability and conductivity.

2. Material Selection & Preparation

• Plastic Housing: Typically made from high-performance thermoplastics like PBT or PA66 for heat and chemical resistance.

• Metal Contacts: Made from copper alloys (e.g., brass, phosphor bronze) with coatings like tin, gold, or silver for improved conductivity and corrosion resistance.

3. Stamping (Metal Terminals)

• Thin metal sheets are stamped into precise terminal shapes using high-speed presses.

• These terminals may go through plating for conductivity and corrosion resistance.

4. Injection Molding (Plastic Housing)

• Plastic granules are melted and injected into molds to form connector housings.

• Molded parts are cooled and ejected, then inspected for defects.

5. Assembly

• Stamped terminals are inserted into plastic housings either manually or via automated assembly machines.

• Additional components like seals, gaskets, and locks are added to improve environmental protection.

6. Testing & Quality Control

• Electrical Testing: Checks conductivity, resistance, and insulation.

• Mechanical Testing: Ensures proper fit, retention force, and mating cycles.

• Environmental Testing: Simulates conditions like heat, humidity, and vibration to ensure durability.

7. Packaging & Distribution

• Finished connectors are packaged in trays, reels, or bulk containers.

• They are labeled and shipped to automotive manufacturers (OEMs) or aftermarket suppliers.