Aerospace Connector Pins | Zero-Scrap Cold-Form Manufacturing

Electropin achieves a defect rate of just 1 pin per 600,000,000 produced. Because cold-form die rolling tools do not dull or degrade over time as cutting tools do, dimensional accuracy remains constant throughout the entire production run, regardless of order volume.

Yes. All Electropin connector pins are manufactured from lead-free materials, including lead-free brass and stainless steel. This fully eliminates REACH and RoHS compliance concerns, unlike traditional machined pins that often require leaded brass to achieve acceptable tool life and dimensional tolerances.

Electropin produces connector pins in lead-free brass and stainless steel as standard material options. Other metals are available depending on the application. Lead-free brass is suited for most electrical contact applications, while stainless steel is selected for applications requiring higher hardness or corrosion resistance.

When raw materials are available, Electropin can begin manufacturing and deliver a first batch in as little as two weeks. Subsequent batches are delivered on a customer-specified timeline. Production can also be scaled dramatically if volume requirements change, with output reaching up to 5 pins per second.

Retention features available include Star (which can achieve up to 50% greater diameter than the wire raw material), Tabs or Spline, Inscribed Square, and Flat. These features provide anti-rotation and high retention strength for press-fit into metal, post-insertion into plastic, and through-hole PCB mounting applications.

Yes. Electropin offers a collaborative Design for Manufacturing (DFM) consultation process where Keith Brenton and the engineering team work directly with procurement, product designers, and engineers to refine pin geometry for optimal manufacturing outcomes. Custom die molds are created to meet exact dimensional and functional requirements.