Detailed Explanation of the Manufacturing Process of In-Die Riveted Moving Contact Assembly Microswitches

The In-Die Riveted Moving Contact Assembly is the core metal functional unit for microswitches, enabling stable electrical switching and durable operation for millions of cycles. The entire production chain relies on four standardized processes for mass production: stamping, precision riveting, automated assembly, and multi-dimensional performance testing.

Riveted Contact Terminal Assembly uses special conductive and elastic metals such as copper, with dimensional tolerances controlled throughout the process to ±0.01~±0.03 mm, preventing batch failures such as contact loosening, spring deformation, and excessive contact resistance.

Stamping is the first step in the manufacturing of the Silver Contact Riveted Copper Assemblies, primarily used to process metal components such as contact supports, springs, and terminals.

1. Material Selection: Springs are mostly made of copper, with a thickness of 0.1–0.3 mm; the contact substrate commonly uses silver alloys (AgNi, AgSnO₂) to improve conductivity and arc resistance.

2. Equipment and Process: High-speed punching machines are used in conjunction with slow wire EDM dies to achieve dimensional accuracy of ±0.01 mm.

Multi-station progressive dies can complete blanking, punching, bending, and forming processes in one go, with an efficiency of hundreds of pieces per minute.

3. Quality Control: After stamping, the Silver Bimetal Rivet Stamping Part undergoes a full inspection to eliminate defects such as burrs, deformation, and cracks, ensuring consistency in subsequent assembly.

Riveting is the core process for forming the Electrical Contact Rivet Assemblies and connecting multiple metal components (such as springs, contacts, and actuators) inside the microswitch, directly affecting the stability and lifespan of the switch.

Process Principle:

• Axial pressure is used to upset the rivet rod inside the hole to form the head, so that two or more parts are rigidly connected. This process requires no welding, avoids heat deformation, and is suitable for Silver Electrical Riveted Components.

Equipment Types:

• Manual Riveting: Suitable for small-batch trial production, relies on operator experience.
• Spin Riveting Machine: High degree of automation, controllable pressure, widely used in mass production.
• Pneumatic/Hydraulic Riveting Machine: Suitable for high-strength, high-consistency requirements.

Key Control Points:

• The riveting force of the Electrical Silver Contact Rivets Copper Contacts Assembly needs precise control. Excessive force will cause spring deformation, while insufficient force will loosen the connection.
• After riveting, the travel and trigger force must be checked to ensure they are within tolerance (typically ±0.03mm).
• Some high-end products employ "floating riveting" technology to compensate for minor assembly errors and improve consistency.

1. Assembly is the process of integrating stamped parts, Electrical Riveted Contact Sub‑Assemblies, and injection-molded housings to form a complete switch structure.

2. Automation Level: Fully automated assembly lines can be built, with robotic arms handling spring installation, contact positioning, and housing pressing. Humans are only responsible for loading, unloading, and random inspection.

3. Key Steps
Place the Copper Carrier Riveted Silver Contact Assemblies into the lower housing.
Install the drive rod and spring.
Press the upper housing and seal using ultrasonic welding.
Insert and secure the terminals.

Every microswitch equipped with the Precision Stamped Riveted Contact Assemblies must undergo multi-dimensional testing before leaving the factory to ensure performance meets standards.

The entire production process can achieve full-process control from mold to finished product, keeping the Electrical Contact Riveting Assembly defect rate below 0.1%.

We have our own complete high-speed stamping, precision riveting, automated assembly, and full-area environmental testing production lines. We can independently complete the entire process of In-Die Riveted Moving Contact Assembly mold opening, sampling, and batch delivery, meeting the large-volume, stable supply needs of new energy and industrial control equipment. If you are struggling with issues such as excessive dimensional tolerances, unqualified durability tests, and delayed delivery from existing contact suppliers, please send drawings, parameters, and purchase quantity inquiries immediately.