Overmoulded contact

Leadframe stamping & overmoulding

Medium to larger volumes overmoulded electrical contacts at a reasonable price in high precision quality. This integrated request KeyTec can fulfil with its in house competence of precision stamping coil material to reel lead frames , partial reel to teel plating (tin, silver, etc.) and implementation of a process where parts from reel are multiple cavity overmoulded.

Not only small copper structures can be stamped and overmoulded, also larger connector components and even a bobbin for coil can be moulded on small contacts.

For the realization of these specific parts, KeyTec does not stop by the stamping and bending in the presses, also bending as step before of even in the mould are techniques that are familiar and in use.

Stamping and moulding integrated under one roof

Electrical systems, either in the industry or automotive, require the distribution of the electrical power. The mainly used carrier in this perspective are copper or copper alloy based parts, busbars connecting the different power sources and users.

As explained in the power distribution (link) solutions, KeyTec realized specific processing for these kinds of multi-level parts. In addition to the stamping, bolts assembly, KeyTec also adds its injection moulding capability to make customer specific power distribution parts.

With this one roof concept for these specific products, the customer has only one contact for the complete assembled part, copper material – stamping – (pre- or post-)plating – bolt assembly and overmoulding this subassembly to an isolated power distribution assembly.

Challenges like burr direction in relation to the clamping position in the injection moulding tool, material displacement during bolt assembly and tolerance stacks are technical challenges that are solved by the multi-disciplinary engineering team from KeyTec.

With its specialism in special engineering plastics (e.g. reinforced with glass fiber up to 35%, flame retardant additives), a part is made to withstand its challenges in the field.