Die Stamped Selective Silver Plated Terminal Gang for Automotive Application

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Intended for use in a cylinder reduction application, the second generation version of this insert molded automotive terminal set required an added silver plating for the terminals. Wiegel Tool Works engineered a way to reduce the amount of silver used by 35 percent, thus reducing overall cost and saving silver.

The original terminals were manufactured from copper-based engineering grade material, C19025, with spring properties. The terminals underwent progressive die stamping, and a plastic clip was inserted in-die. Next, the terminals were selectively plated using tin and silver. The design for the project was formatted as STEP file, converted for use with UG Die Wizard Software, so that all processes could be carried out according to precise customer requirements: the tightest tolerance upheld was +/- .001". 500,000 to 950,000 terminal sets were manufactured over the course of a year, and delivered according to customer specified just-in-time requirements.

Specifications

Product Description:	This copper based terminal set had engineering grade material called out; C19025
Capabilities Applied/Processes:	Progressive die stamping; auto-insertion of a plastic clip
Tightest Tolerance:	±.001"
Material Thickness:	.016"
Material Used:	C19025; copper based engineering grade material with spring properties
Material Applied:	Selective silver and tin plating
Industry for Use:	Automotive; Fuel economy
Volume:	500,000 to 950,000 per year
Delivery Time:	JIT
Delivery Location:	USA
Standards Met:	Customer supplied print; 3D Database
Product Name:	Terminal gang; connector
Project Scope:	Design and stamp terminal for cylinder reduction application
Design Work:	STEP file conversion for use with UG Die Wizard software
Special Tooling:	Insertion of plastic clip in-die, Sub Component dies
Special Packaging	Returnable packaging; Stacked in sets of 4