Die Stamped Copper and Brass Large Insert Molded Lead-Frames for Automotive Transmission

Wiegel Tool Works manufactured these copper-based lead-frames for use in transmission electronics. The lead-frame tools can be up to 120" long, and feature up to 248 punches to provide exact dimensions for numerous shut-offs. We first designed and built the tooling, using a 3D database design, and then began manufacturing with progressive die stamping and straddle cuts, with C194 copper and C260 brass as the base materials. We then applied tin plating, via electroplating. Several special tooling requirements were accommodated by using 15 sensors, up to 7-sub component dies, 5 plate dies, nitrogen packs to provide exact pressure, and adjustable forms. After manufacturing, we high-pressure washed the lead-frames, and conducted in-house testing to check for contaminants. The lead-frames were packaged in trays for robotic handling, and delivered according to our client's just-in-time program, one to twice per week, over the course of a year. In total, we produced 300,000 to 1,000,000 lead-frames.