Custom Precision Metal Stamping Spring Contact for Battery Case Usage

Overview

Our custom precision metal stamping spring contacts are engineered for critical electrical connections in battery modules and packs. Manufactured from high-performance alloys, they offer stable contact force, low resistance, and long-term reliability in demanding EV and energy storage applications. We provide full OEM solutions tailored to your specific electrical and mechanical requirements.

Characteristics

Production Process

1. Material Selection & Blanking: High-conductivity, high-elasticity alloy strips (e.g., BeCu, Phos Bronze) are selected and precision blanked.

2. Progressive Stamping & Forming: The strip feeds through a multi-station progressive die, performing piercing, bending, coining, and forming the intricate spring geometry in one continuous process.

3. Heat Treatment (Aging/Tempering): For materials like BeCu, a controlled heat treatment process is applied to achieve the specified spring temper, hardness, and stress relaxation resistance.

4. Deburring & Surface Preparation: Parts are tumbled or chemically deburred to remove sharp edges, ensuring safety and preparing the surface for plating.

5. Precision Plating: Electroplating (Gold, Silver, Nickel, or Tin) is applied to critical contact surfaces to ensure low and stable contact resistance, solderability, and corrosion protection.

6. 100% Functional & Dimensional QA: Every contact undergoes automated optical inspection (AOI). Sample batches from each lot are tested for contact force vs. deflection curve, electrical resistance, and plating thickness.

7. Packaging: Contacts are packaged in anti-static, compartmentalized trays or reel-to-reel packaging to prevent damage and facilitate automated assembly.

Why Choose Us?

1. Expertise in High-Performance Spring Contact Design: Our engineering team specializes in designing and manufacturing contacts that balance electrical performance, mechanical life, and force requirements specific to battery interconnection challenges.

2. Vertical Integration from Die to Delivery: We design and build our own precision progressive dies in-house, allowing for complete control over quality, rapid prototyping, and design optimization for manufacturability and cost.

3. Stringent Quality Focused on Electrical Reliability: Adhering to IATF 16949 standards, our process includes SPC monitoring and critical electrical/mechanical testing to guarantee performance consistency in safety-critical applications.

4. Comprehensive Testing & Validation Support: We provide full test reports (force-deflection, contact resistance, plating thickness, salt spray) with initial samples and production batches, supporting your product validation process.

5. Proven Partner for Automotive & Energy Sectors: Our experience in supplying mission-critical components for EVs and储能 systems makes us a reliable partner for your battery pack supply chain.

Factory Show

Our dedicated stamping facility is equipped with high-precision, high-speed progressive stamping presses and precision slide forming machines. We operate an in-house tool and die shop with CNC, Wire-EDM, and grinding centers for die manufacturing and maintenance. A controlled-environment plating line handles selective and reel-to-reel plating. Our quality lab is equipped with micro-ohm meters, digital force testers, coating thickness gauges (XRF), and salt spray test chambers. Operating under an IATF 16949 certified system, we ensure the production of reliable, high-performance spring contacts for the most demanding applications.