Micron level precision and high-speed automated manufacturing

The Precision Stamping Process of Terminals: Micron-Level Manufacturing Technology

2026-07-20

Precision terminal stamping isn’t just about cutting metal to shape—it’s really about holding a micrometer-level tolerance, hit after hit, at high speed. On the shop floor, we run servo presses equipped with high-speed progressive dies, typically somewhere between 200 and 1,500 strokes per minute. What looks like a blur to the naked eye is actually a tightly choreographed sequence: contact springs, barbs, locking tabs—all formed in one continuous flow, without stopping to reposition the strip.

Getting this right comes down to three things we never compromise on.

First is the tooling itself. Our dies are built to absurdly tight specs—think ±0.002 mm—using precision wire EDM and meticulous hand polishing. We also keep a very close eye on die clearance, usually holding it to just 2–3% of the material thickness. That’s what gives you a clean shear edge and keeps burrs to a minimum, rather than relying on secondary trimming later.

Then there’s the material behavior. We work mainly with high-performance copper alloys—phosphor bronze C5191, beryllium copper C17200—chosen for both conductivity and spring properties. But the real challenge is managing how the metal reacts under stress. Bending isn’t just a set-and-forget step; we have to account for springback so the final geometry stays exactly where it needs to be.

Finally, quality isn’t something we “check at the end.” Our lines are tied into online CCD vision systems and laser thickness monitors. Every terminal is measured against strict criteria—dimensions, plating thickness, mechanical strength—so we’re not shipping parts that merely “look fine.” In practice, this lets us hold defect rates well below 50 PPM, which matters when your terminals are going into automotive or high-end electronics.

Prochain :
High-Speed Metal Stamping in Action

The Precision Stamping Process of Terminals: Micron-Level Manufacturing Technology​

The Precision Stamping Process of Terminals: Micron-Level Manufacturing Technology