Custom Connector Pins for Automotive Electronics | Cold-Formed | Manufacturer

Electropin manufactures custom connector pins in lead-free brass and stainless steel, as well as other metals upon request. Lead-free brass is a softer material suited to most connector applications, while stainless steel offers greater hardness for demanding environments. All material options eliminate the need for leaded brass, keeping production fully REACH and RoHS compliant.

Cold-forming, or automatic die rolling, shapes metal by pressing it through precision dies at room temperature — no cutting or heat is involved. Unlike machining, cold-forming produces zero scrap because all raw material becomes finished pins. Tools do not dull, so dimensional accuracy is maintained from the very first pin to the millionth, eliminating the quality drift common in machined parts.

Electropin offers four primary retention feature options: Star, Tabs/Spline, Inscribed Square, and Flat. The star feature can expand pin diameter up to 50% greater than the original wire diameter, providing exceptional pull-out resistance. These features prevent rotation and ensure secure seating in plastic housings, metal parts, and PCB through-hole applications.

Electropin's custom connector pins support three primary mounting methods: press-fit into metal, through-hole PCB mounting, and post-insertion into molded plastic parts. Grooved and hinge pin designs also support high-speed automation assembly lines where pins must slide down tracks without precise orientation, making them well-suited for high-volume connector manufacturing environments.

When raw materials are available, Electropin can begin production and deliver the first batch of cold-formed pins in as little as two weeks. Subsequent batches are delivered on a customer-specified timeline. Production volume can also be scaled dramatically to accommodate changes in demand, making Electropin a flexible partner for both prototype and high-volume programs.

Yes. Because Electropin uses lead-free brass and other non-leaded metals, all applicable products are REACH and RoHS compliant. Unlike traditional machined connector pins that typically require leaded brass for machinability, cold-formed pins do not need leaded alloys, eliminating hazardous substance concerns and simplifying regulatory documentation for automotive and medical OEMs.