Connector pins for 5G equipment are tiny, often less than 3 mm long, and they must fit into housings with almost no clearance. The die that makes them needs a level of alignment that ordinary stamping tools cannot deliver. We use a four-post ball-bearing guide system and hardened guide bushings to keep the upper and lower halves in perfect registration, stroke after stroke.
Thin copper alloy strip tends to curl or twist when it is punched at high speed. To control this, our die includes a strip stabilizer that holds the material flat right before the cutting station. We also set the cutting clearance to a percentage of material thickness that is specific to copper alloys, not the general clearance used for steel. This produces a clean break with minimal burr height.
Because pins are so small, a single misaligned punch can scrap thousands of parts before anyone notices. We build in a misfeed detection sensor that stops the press immediately if the strip shifts out of position. The die also features quick-change punch cassettes, so a worn pin punch can be replaced in under five minutes without removing the entire die from the press.
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