Riveting Contact Assembly

Our company focuses on the research, development, and production of Riveting Contact Assembly, covering four series: Copper In-Die Riveting; Brass In-Die Riveting; Beryllium Copper In-Die Riveting; and Stainless Steel In-Die Riveting. These Riveting Contact Assembly meet the needs of multiple fields, such as power, new energy, and industrial equipment.

1. Copper In-Die Riveting

As the core conductive Copper Contact Rivetings of low-voltage electrical appliances, the performance of copper stamping parts directly affects terminal products' reliability and service life. The copper stamping parts we produce have the following significant technical characteristics:

1.1 In terms of Materials Science

We select high-purity copper strips such as C1100 and T2Y2, with a copper content of ≥99.99%, to ensure excellent conductivity (conductivity ≥98% IACS) and thermal conductivity. Develop a series of material solutions for different application scenarios:

1.2 In terms of Precision Forming Technology

The progressive die stamping process for Copper Stamping With Riveted Silver Contacts achieves dimensional accuracy control of ±0.01mm. Through the design of multi-station progressive dies, multiple methods such as punching, bending, and forming can be completed in a single stamping stroke, with a production efficiency of 200 - 300 times per minute. The core "micro-deformation" stamping technology features:

Optimizing the blanking clearance (controlled at 5 - 8% of the material thickness)
Adopting a double-sided shearing process
Increasing the proportion of the bright zone on the cutting surface to more than 85% greatly reduces subsequent processing requirements

1.3 In terms of the Surface Treatment Process

1.4 Analysis of In-Mold Riveting Process for Silver Contacts

The reliable connection between silver contacts and the copper substrate is crucial for the long-term stable operation of electrical components. Our technology has achieved revolutionary process breakthroughs:

(1)  In terms of Structural Design

(2)  In terms of Process Control System
The in-mold riveting process for silver contacts in progressive die stamping realizes full-process parameter monitoring:
The multi-axis force control system controls the riveting pressure accuracy within ±1.5%.
Ensures the consistency of the forming quality of each riveting point.

1.5 The Advancement of Technical Processes
Our production processes demonstrate leading technical levels in multiple dimensions:

(1) In terms of Die Technology
The use of cemented carbide progressive dies with a service life of more than 30 million times.
CAD/CAE integrated design enables precise alignment of in-mold riveting stations, with the coaxiality controlled within φ0.015mm.
The original elastic stripper system solves the deformation problem of thin Silver Electrical Riveted Components, achieving a flatness of 0.05mm/100mm.

(2) In terms of Process Control Technology
The production line is equipped with an online machine vision inspection system, conducting 100% full inspection of key dimensions, and the data is uploaded to the MES system in real time for quality traceability.
The intelligent adjustment system automatically optimizes stamping parameters according to the characteristics of material batches, ensuring process stability.

(3) In terms of Energy Conservation and Environmental Protection Technology
The immediate copper scrap recycling system achieves a material utilization rate of more than 85%.
The cyanide-free silver plating process and wastewater closed-loop treatment system comply with RoHS and REACH environmental protection standards, guaranteeing access to high-end European and American markets.

1.6 Application areas and quality assurance

Application range: relays, switches, contactors, circuit breakers, thermostats, etc.
Certification system: IATF16949, ISO9001.
Laboratory test items:
Conductivity (contact resistance, temperature rise)
Mechanical properties (tensile strength, bonding force)
Durability (mechanical/electrical life)
Environmental reliability (salt spray, damp heat)

2. Brass In-Die Riveting

Brass (such as H65, and H70) has become an ideal material for switch contacts due to its excellent electrical conductivity, mechanical strength, and corrosion resistance. The core technical advantages of our brass stamping parts are as follows:

2.1 Material Science Optimization

2.2 Precision Stamping Forming Technology

Process Efficiency: Progressive die stamping completes multiple processes such as punching, bending, and stretching in a single die stroke, with an efficiency of 200 - 400 times per minute.

Precision Control:

Core Value: Reduces burrs, enhances electrical contact performance, and meets the precision requirements of high-end switches.

2.3. Surface Treatment and Anti-corrosion

2.4 Matching Capabilities of Brass Stamping, Silver Contact Riveting, and Screw Assembly

We provide one-stop modular Electrical Contact Assemblies Brass Stamped Part services of "stamping - riveting - assembly":

(1) Precision Integration Technology

(2) Screw Fastener Optimization

Specification Range: M2 - M10 stainless steel/copper screws
Reliability Design:
Torque control accuracy ± 5% (prevents loosening and stripping)
Optional threadlocker or lock washers (stable in vibrating environments)

(3) Automated Detection System
100% Quality Control:
CCD visual positioning: Detects screw screwing position
Torque sensor + micro-ohmmeter: Simultaneously detects mechanical and electrical conductivity performance

3. Beryllium Copper In-Die Riveting

Beryllium copper (BeCu), characterized by high strength, high elasticity, fatigue resistance, and corrosion resistance, is an ideal material for critical components such as relay moving reeds and microswitch spring pieces. The core technical advantages of our beryllium copper stamping parts are as follows:

3.1 Technical Characteristics of Beryllium Copper Stampings

(1) Material Science Optimization

(2) Precision Stamping Technology

Dimensional Accuracy: Progressive die stamping achieves ±0.01 mm precision, suitable for 0.05–0.3 mm ultra-thin BeCu strips to prevent cracking/deformation
Die Technology:

Surface Quality: Smooth cut surfaces reduce post-processing, meeting direct precision Beryllium Copper Punch Contact Riveted Terminals requirements

3.2 Automotive-Grade High-Efficiency Assembly Technology

For precise assembly of BeCu moving reeds + silver contacts + armature stampings in automotive relays and high-end switches, we achieve integrated production:

(1) Three-in-One In-Mold Riveting Process

Fully Integrated in Single Progressive Die:
1. BeCu moving reed stamping (high-elasticity structure forming)
2. Automatic silver contact riveting (low-resistance connection)
3. Precision assembly of armature stampings (rigid support positioning)

Efficiency Gains: Shortens production cycle by 50% and reduces labor costs by 60% compared to traditional multi-step assembly
 

(2) Precision Positioning & Automation

4. Stainless Steel In-Die Riveting

As a professional manufacturer of stainless steel stamping parts and in-mold riveting of silver contacts in China, we have focused on precision progressive die stamping and integrated in-mold riveting technology for silver contacts for over 20 years. Our core competitive advantages are as follows:

4.1 Dual-Driven by Materials and Processes

4.2 Precision Progressive Die Stamping Technology

Full-Process Integration Capability:

Multiple-station progressive dies complete punching, bending, forming, and riveting in one go (reducing 3+ intermediate processes)
Micro-Riveted Components processing capability (minimum feature size 0.3mm, thickness 0.08 - 2.0mm)
Balance between Efficiency and Precision:
Automated feeding system: strip positioning accuracy ±0.01mm
Stability of high-speed punching machines: defect rate < 0.1% during continuous production at 300 strokes per minute

4.3 Surface Treatment Solutions

4.4 Advancement of In-Mold Riveting Technology for Silver Contacts

(1) Comparison of Process Principles

(2) Four Quadrants of Technical Advantages

Mechanical Performance: Shear resistance of riveting points ≥ 50N (when silver contact specification is φ2.0mm), no loosening after 100,000 vibration tests
Electrical Conductivity: Contact resistance ≤ 50μΩ (20% lower than welding process), temperature rise test ΔT ≤ 30K
Production Efficiency: Single-station integration reduces 2 processes, 100% automation rate, yield increased to 99.5%
Environmental Compliance: No use of soldering fluxes or adhesives, carbon emissions during production reduced by 60%

1. Deeply cultivating the industry for 30 years, technical solutions directly hit the pain points of the industry
Experienced technical accumulation: The core technical team comes from the world's leading company in the relay field, focusing on the field of electrical connection for 30 years, deeply mastering the material characteristics and failure mechanisms of low-voltage electrical appliances, new energy, and other scenarios, and can provide efficiency-enhancing and cost-reducing solutions and innovative technology introduction (such as cadmium-free Silver Contact and Stampings, high thermal conductivity welding process)

Full category manufacturing matrix: Mainly engaged in riveting/welding silver contacts, tungsten copper contacts, relay cores, and more than 100 kinds of precision metal In-Die Rivet Electrical Contacts, adapting to traditional low-voltage electrical appliances such as circuit breakers and relays and emerging fields such as new energy vehicles and energy storage equipment, to achieve one-stop supporting services

2. Global service network, rapid response to create value
Seven major international bases: Layout Barcelona (Europe and the United States), Tehran (Middle East), New Delhi/Port Klang (Southeast Asia), Tokyo (Japan and South Korea), and other strategic locations, providing 24-hour local docking, credit support and after-sales response, breaking through cross-border cooperation barriers

Agile delivery system: samples are sent quickly within 1-2 days, the development cycle is compressed to 20-30 days, and mass production orders are delivered within 15-20 days (production is completed upon receipt of payment), accurately matching customer R&D and mass production rhythm

3. Vertical integration of the industrial chain, quality, and cost

Full process integration: master 12 core processes such as cold stamping and laser welding, and realize full-process closed-loop production from raw materials to finished products, with a yield rate of >99.99%, and a comprehensive cost of 10-15% lower than that of peers

Smart manufacturing cluster layout: annual output value of new energy is 120 million, annual output value of low-voltage electrical appliances is 80 million, three major production bases in Xiamen (new energy stamping parts/silver contact components/relay cores) + two major professional factories in Ningbo (mold development/precision processing), forming a professional division of labor system

4. All-dimensional quality assurance, international certification escort

Full process quality control: passed IATF 16949 automotive-grade quality management system certification, implementation of RoHS/REACH environmental standards, full traceability from raw material screening (electrolytic copper purity ≥ 99.95%) to finished product testing

Data-based quality control: Provide material composition report (COA), and process statistical control (SPC) data package to ensure product consistency by international standards such as UL and VDE

5. Hard-core intelligent manufacturing foundation, escorting large-scale mass production
Independent manufacturing system: 7 major professional workshops (stamping/welding/molds, etc.) are 100% independently operated, with technical backbones accounting for more than 30%, achieving zero outsourcing of core processes

Intelligent equipment cluster: Equipped with hundreds of high-end equipment (multi-station cold heading machines/laser welding robots, etc.), the annual processing capacity exceeds 1 billion pieces, with both large-scale mass production and high-end customized production capabilities

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