Connector Pins | High-Speed Cold-Form Manufacturing | Precision Supplier

Connector pin size is measured by outer diameter (OD) of the shank, overall length, and — where applicable — the diameter of any retention feature such as a star or spline. For cold-formed pins, the star retention feature can achieve up to 50% greater diameter than the wire raw material, so both the shank and retention zone diameters should be specified.

Electropin manufactures connector pins in lead-free brass and stainless steel as standard material options, with other metals available upon request. All lead-free offerings eliminate REACH and RoHS compliance concerns, making them suitable for regulated industries such as automotive, medical devices, and consumer electronics.

Electropin offers four retention feature types: Star, Tabs/Spline, Inscribed Square, and Flat. These features provide anti-rotation and high pull-out resistance for press-fit into metal, post-insertion into molded plastic, and through-hole PCB mounting applications. The star feature can expand the effective diameter by approximately 50% over the wire diameter.

Electropin does not publish a minimum order quantity; pricing and quantities are available on request. First-batch delivery can begin in as little as two weeks when raw materials are available. Production is highly scalable, so volumes can be increased significantly as customer demand grows over time.

Cold-form (automatic die rolling) manufacturing displaces no material — the raw wire is formed rather than cut, producing zero scrap and eliminating tool dulling. Machined pins generate chips and require regular retooling. Electropin's cold-form process achieves a defect rate of 1 in 600,000,000, faster throughput (up to 5 pins/sec), and lower per-unit cost than conventional machining.

Electropin's connector pins serve automotive connectors, medical device assemblies, farm equipment electrical systems, PCB and circuit board manufacturers, computer and electronics OEMs, and molded plastic part producers. The full product range — including solid, PCB, press-fit, barbed, grooved, knurled, hinge, gauge stop, and dowel pins — is designed to meet the specific demands of each sector.