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Connectors Production

Precision-Engineered Connectors for Power, Signal & Data Transmission

At Ge-Shen, we specialize in the design and production of high-performance electrical connectors used across industries such as automotive, industrial automation, consumer electronics, medical devices, and telecommunications.

Whether you need standard housings, custom pin layouts, or application-specific terminal designs, our in-house team and production facilities are ready to deliver.

Production of Connectors

1. Design & Engineering

Every connector begins with a custom design tailored to your application’s electrical, thermal, and mechanical requirements.

• 3D CAD modeling and simulation
• Custom pin layouts and housing features
• Material selection for plastic and metal components
• Prototype samples available within weeks

2. Mold and Tool Fabrication

We create precision molds and stamping tools in-house or with qualified partners to ensure component accuracy and longevity.

• CNC machining and EDM for mold creation
• Progressive dies for high-speed stamping
• Tool maintenance for long-term production reliability

3. Plastic Injection Molding

The connector housings are manufactured using injection molding machines, forming the exact shape and features needed for secure connections.

• Materials: Nylon 6/6, PBT, LCP (UL94-V0 flame retardant grades)
• High-precision molds for tight tolerances
• Optional keying, locking, and branding features

4. Metal Terminal Stamping

Metal contacts are made from high-conductivity materials such as phosphor bronze, brass, or beryllium copper, using high-speed stamping equipment.

• Custom crimp, solder, or press-fit terminals
• Surface finishes: tin, gold, or silver plating
• Rolled and heat-treated for spring tension and durability

5. Assembly

We integrate housings and terminals through automated or semi-automated assembly lines.

• Terminal insertion into housings
• Crimping wires to terminals (where applicable)
• Cable termination and harnessing (optional)

6. Quality Control

Every connector undergoes rigorous testing to ensure reliability in real-world conditions.

• Electrical continuity and resistance testing
• Pull-force and insertion testing
• Visual and dimensional inspection
• Environmental durability checks (humidity, vibration, etc.)

🔍 Why Terminal Fabrication & Insertion Is Most Critical:

1. Electrical Reliability

• The metal terminal is what actually conducts the signal or power.
• Poor contact can cause voltage drops, intermittent connections, or even system failure.

2. Precision Matters

• Terminals must be stamped, formed, and plated with micrometer-level precision.
• Misaligned or poorly formed terminals lead to mating failure or poor contact pressure.

3. Material and Plating

• Choosing the wrong alloy or plating (e.g., tin vs. gold) can cause:
  • Corrosion
  • Oxidation
  • Signal degradation (especially in data connectors)

4. Crimping or Soldering

• For wire connectors, the crimp joint is a critical weak point.
• Improper crimping leads to loose wires, electrical resistance, or shorts.
• High-end crimping requires tightly controlled force and die geometry.

5. Insertion Into Housing

• Terminal retention and alignment must be perfect.
• Loose or misaligned terminals can get pushed out during mating or cause pin bending.

Summary:

Stage	Criticality	Why It Matters
Terminal Stamping & Insertion	⭐⭐⭐⭐⭐	Directly affects electrical and mechanical reliability
Mold Making	⭐⭐⭐⭐	Ensures part consistency and housing fit
Injection Molding	⭐⭐⭐	Affects mating quality and heat resistance
Assembly	⭐⭐⭐	Ensures durability and usability
Testing	⭐⭐⭐⭐	Detects failures before shipping

What we offer?

• Connectors production
• Design & development of custom pin layout
• Process upgrading & automation
• Testing
• Housing design & fabrication
• Assembly service