Bullet Electrical Terminals | Lead-Free Cold-Formed | Manufacturer

Cold-forming, specifically Automatic Die Rolling, shapes wire material by rolling it through dies without cutting or heating. Unlike machining, no material is removed, so there is zero scrap. Tools do not dull during the process, ensuring dimensional consistency from part one to part one million — a significant quality advantage over conventional machined pins.

Yes. Because Electropin's cold-forming process uses lead-free brass and stainless steel exclusively, no leaded alloys are required. This eliminates the regulatory thresholds that apply to machined brass pins, making every pin produced fully compliant with REACH and RoHS without requiring additional material substitution or documentation overhead.

Electropin offers four retention feature types: Star, Tabs (Spline), Inscribed Square, and Flat. The star feature can expand the effective diameter up to 50% beyond the base wire diameter, providing strong press-fit retention. Each feature is designed to prevent rotation and ensure secure seating in metal, PCB, or molded plastic housings.

When raw materials are available, Electropin can begin manufacturing and deliver a first batch of custom cold-formed pins in as little as two weeks. Subsequent production batches are scheduled on a customer-specified timeline, and production volume can be scaled dramatically when demand changes without significant retooling lead time.

Electropin's pins support three primary mounting methods: press-fit into metal substrates, through-hole PCB mounting for circuit board assembly, and post-insertion into molded plastic connector housings. Hinge and grooved pin designs also support high-speed automation track feeding, where pins slide down tracks without requiring precise orientation.

Yes. Electropin offers a collaborative Design for Manufacturing (DFM) consultation process led by engineers with over 35 years of experience. Custom dies are created for each specification. The process covers design refinement, retention feature selection, material choice, and performance validation to ensure the final pin is optimized for both function and cost-efficient production.