EV High-Voltage Connector Terminal Stamping: C5191 Phosphor Bronze, 0.15mm Stock, 500K pcs/Month
In an EV high-voltage connector, the terminal is the throat of the whole circuit. Slightly higher contact resistance means more heat; slightly weaker material spring means loose contacts after a few hundred insertions. What customers demand from a stamping supplier is never just "can you punch it out" - it is that 500,000 pieces a month all look exactly the same.
Project Background & Challenge
An automotive electronics manufacturer in South China was sourcing terminals for high-voltage connectors: C5191 phosphor bronze, 0.15mm stock, silver-plated contact area, 10,000+ insertion cycles, monthly demand of 500,000 pieces. Their previous supplier handled thick-stock terminals fine, but on thin stock the burrs grew at high speed, bending springback drifted, and dimensions shifted between batches.
Thin-stock terminals have three traps: burr ratio (the thinner the stock, the more visible the burr), springback (phosphor bronze springs well, but the compensation is hard to predict), and plating protection (scratching the silver layer during stamping wastes the plating entirely).
BQUQ Process Solution
Our approach: one progressive die, one pass, in-line inspection - minimal human intervention in the process.
Die Design
A 24-station progressive die: blanking, sizing, bending and forming split across stations. Bending stations are pre-overbent with springback compensation from tryout data. Die sections are powder metallurgy high-speed steel with vacuum heat treatment, designed for a 20-million-stroke die life.
Production & Inspection
Produced on a high-speed press at up to 400 SPM with in-die fiber-optic sensing and automatic rejection. Terminal pitch is measured in-line by CCD; samples go to a profile projector for verification. Plating quality is checked by salt spray and coating thickness sampling per batch.
Key Specifications
| Item | Specification |
|---|---|
| Material | C5191 phosphor bronze, silver or tin plating available |
| Stock thickness | 0.10-0.30mm |
| Terminal pitch | ±0.02mm |
| Burr height | ≤0.02mm |
| Press speed | Up to 400 SPM |
| Volume | From 500K pcs/month; die life designed for 20M strokes |
| Inspection | In-die fiber optic + in-line CCD, profile projector sampling, salt spray & coating thickness checks |
| System | ISO9001:2015 |
Quality Control & Delivery
First and last articles are fully checked per batch, processes are monitored by SPC, and shipments include material certificates and inspection reports. Pilot run of 20,000 pieces delivered in 10 days; after customer validation we moved to rolling volume schedules.
Related Products & Resources
To see more parts in this category and how we scale them, browse the Stamping Terminals & Contacts category page, or these related products:
Related Q&A: What Is Driving the Growth of Stamped EMI Shielding Parts?. More manufacturing Q&A is in our FAQ Center.
For our capabilities, equipment and quality system, visit About BQUQ and Factory Strength.
FAQ
What burr level can you hold stamping 0.15mm stock terminals?
Burr height is controlled within 0.02mm. That comes from precise die clearance ratios and disciplined cutting-edge maintenance - the die is re-sharpened on a stroke schedule so it never runs with a worn edge.
How do you solve phosphor bronze springback?
Bending stations are pre-overbent using compensation values measured during tryout. Once locked in for production, the parameters are re-verified whenever a new coil is loaded.
Does stamping damage the silver plating?
Lubrication and die surface finish are optimized for plated strip. Coating thickness and salt spray are sampled per batch, and parts ship only when they meet the drawing requirements.
