FPIC’s Precision Metal Terminals Redefine Reliability for New Energy Vehicles

In the rapidly evolving world of electric vehicles (EVs) and energy storage systems (ESS), every connection matters. Behind the silent efficiency of a battery pack lies a complex web of conductors, sensors, and signal interfaces — all of which must perform flawlessly under vibration, heat, and extreme environmental conditions.

Traditionally, engineers relied on solder joints to attach sampling wires or signal leads to printed circuit boards (PCBs). However, as vehicles endure long-term vibration and frequent temperature changes, solder points can crack, loosen, or fail — leading to signal interruptions, system alarms, and even vehicle shutdowns.

To eliminate this hidden risk, the industry has embraced a new generation of eyelet terminals (also known as fish-eye terminals) — a zero-solder, press-fit connection technology that has become the benchmark for safety and reliability in modern EV battery systems.

1️⃣ Zero-Solder Technology for Reliable, Long-Term Connections

Eyelet terminals replace traditional soldering with mechanical press-fit technology.
Each terminal is precisely inserted into a plated through-hole on the PCB, forming a gas-tight, cold-welded mechanical bond without heat or solder.

This approach eliminates problems like cold joints, thermal stress, and oxidation, ensuring stable electrical conductivity throughout the battery’s life cycle.
For high-current and high-vibration applications, it offers a proven reliability advantage — meeting the demanding standards of automotive-grade safety.

2️⃣ Optimized Contact Design for Signal Integrity

The terminal’s unique spring-like geometry maintains constant pressure within the hole, minimizing contact resistance and ensuring low temperature rise even under heavy current flow.

By preserving signal integrity in high-load environments, eyelet terminals ensure accurate battery monitoring, voltage sensing, and cell balancing — critical to the safe operation of every EV.

3️⃣ Higher Assembly Efficiency, Lower Manufacturing Risk

Eyelet terminals simplify the manufacturing process by eliminating the need for soldering, flux cleaning, and heat management.
This leads to:
✅ Shorter assembly cycles
✅ Lower defect rates
✅ Improved automation compatibility

For large-scale EV battery production, such as power battery modules and BMS systems, this technology significantly improves throughput, consistency, and process control — perfectly aligning with the industry’s move toward smart manufacturing.

4️⃣ Eco-Friendly Manufacturing for a Sustainable Future

Since no solder or flux is required, press-fit terminal production avoids emissions from solder fumes and reduces waste from cleaning chemicals.
This aligns perfectly with the environmental, social, and governance (ESG) objectives of leading automotive OEMs — supporting green manufacturing and sustainability throughout the supply chain.

5️⃣ Vibration Resistance and Structural Reinforcement

FPIC’s eyelet terminals feature a preformed elastic zone that absorbs vibration and compensates for mechanical stress.
Combined with over-molding technology, this ensures that the terminal remains firmly anchored to the PCB — even under severe vibration and impact.

The result: no loosening, no micro-cracks, and no signal failure, even after tens of thousands of vibration cycles.

6️⃣ Performance in Extreme Environments

Through advanced materials and precision forming, FPIC’s terminals achieve wide temperature tolerance (-40°C to +125°C), excellent corrosion resistance, and stable contact pressure over the product’s full lifecycle.

Whether it’s a fast-charging EV at 125°C, a cold-start at -40°C, or coastal salt-fog exposure, FPIC’s terminals maintain consistent performance and safety.

7️⃣ Full Lifecycle Reliability Testing

Every FPIC eyelet terminal undergoes comprehensive testing in our in-house laboratory, including:

• Insertion & extraction force validation

• Thermal cycling and vibration endurance

• Temperature rise testing

• Corrosion resistance & salt spray testing

• Dimensional inspection via KEYENCE systems

This ensures each part meets the highest standards of IATF 16949, ISO 9001, and VDA 19.1 for automotive components — guaranteeing full traceability and reliability across the production chain.

8️⃣ Expanding Applications in EV and Energy Storage Systems

From battery module assemblies and power distribution units (PDUs) to on-board chargers and energy storage containers, eyelet terminals are enabling modular, maintainable, and scalable designs for the new energy era.

Their plug-and-play, serviceable design not only enhances system safety but also streamlines assembly, repair, and recycling — providing an ideal foundation for next-generation solid-state and sodium-ion batteries.

FPIC: Your Reliable Partner for Automotive Metal Components

At Shenzhen Forman Precision Industry Co., Ltd. (FPIC), we specialize in precision metal stamping, CNC machining, and connector component development for the world’s leading automotive and energy companies.

Our machined eyelet terminals combine precision engineering, material innovation, and mass-production capability to ensure the best balance of performance, quality, and cost efficiency.

With decades of expertise and fully certified systems (IATF 16949, ISO 9001, ISO 14001, ISO 13485, and VDA 19.1), FPIC provides customized terminal designs, prototype development, and mass production solutions — all supported by advanced laboratory validation and automated manufacturing lines.

Press Fit

Connecting the Future of Electrification

As EVs and energy storage systems become smarter and more powerful, every connection must be stronger, safer, and more reliable than ever before.
FPIC’s eyelet terminal solutions are engineered to make that possible — enabling a safer, cleaner, and more efficient electrified world.

📩 Contact FPIC for customized terminal or connector solutions:
[email protected]
🌐 www.fpiconn.com

How Quality, Customization, and Innovation Define the Future of Automotive Connectors

The global connector market continues to evolve rapidly, driven by electrification, energy transformation, and digital intelligence. According to the latest market analysis from leading connector manufacturers such as TE Connectivity, Amphenol, and Aptiv, growth remains uneven across sectors — but automotive connectors, particularly those used in new energy vehicles (NEVs) and energy storage systems, stand out as one of the strongest engines of demand.

As a trusted global connector manufacturer, Shenzhen Forman Precision Industry Co., Ltd. (FPIC) is committed to staying at the forefront of this transformation, providing certified, customizable, and high-performance connector solutions that meet the stringent requirements of modern automotive systems.

Global Market Insights: Three Forces Shaping Connector Demand

1️⃣ Electrification and Energy Storage

The shift toward electric mobility and renewable energy continues to expand the use of high-voltage, high-current connectors. Automotive and energy storage applications now require connectors capable of handling up to 1500V and 400A, while ensuring safety, reliability, and long service life under harsh environmental conditions.

2️⃣ Digital and High-Speed Data Transmission

AI, advanced driver assistance systems (ADAS), and vehicle-to-everything (V2X) communication are creating new demand for high-speed signal connectors with robust shielding and low latency. This trend is further accelerating as automakers adopt intelligent architecture and centralized computing platforms.

3️⃣ Localization and Value Optimization

While global giants such as TE Connectivity and Amphenol lead with large-scale solutions, more OEMs and Tier-1 suppliers are turning to flexible, local manufacturing partners that can offer cost-effective, customized, and audit-ready solutions — an area where FPIC demonstrates significant competitive advantages.

FPIC Automotive Connectors: Precision, Safety, and Innovation

At FPIC, we design and manufacture automotive connector systems that combine mechanical precision, electrical reliability, and environmental endurance.
Our automotive solutions cover a wide range of applications, including battery systems, inverters, on-board chargers, signal and power distribution, and high-voltage harness assemblies.

🔧 Certified Quality

All FPIC automotive connectors are manufactured under globally recognized standards:

• IATF 16949, ISO 9001, ISO 14001, ISO 13485, ISO 45001, and VDA 19.1

• Stringent process cleanliness and quality traceability throughout production

• Fully equipped in-house laboratory for environmental, mechanical, and electrical testing, including:

  • Thermal shock & temperature rise testing

  • Salt spray & vibration testing

  • Insulation resistance & dielectric strength testing

  • X-ray imaging & KEYENCE dimensional inspection

  • Crimp force analysis and plug-in/out durability tests
    

⚙️ Customization for Every Platform

FPIC offers end-to-end customization — from design concept to production:

• IP67/IP68 sealing, EMI shielding, and keying/coding options

• Flexible pin layouts, plating thickness, and housing configurations

• Integration with wiring harness assemblies for complete energy systems

Our engineering team collaborates closely with customers to deliver prototype samples, validation testing, and mass production readiness according to PPAP, APQP, and DFMEA processes.

🔬 Innovation in Development

FPIC’s R&D center continuously develops next-generation automotive connectors for EV and ESS platforms — balancing high current-carrying performance, compact design, and cost efficiency.
Ongoing projects include 1500V 400A energy storage connectors, combining enhanced conductivity with improved safety and reduced assembly complexity.

Why OEMs and Tier-1s Choose FPIC

✅ Certified Quality Systems – IATF 16949 and VDA 19.1 ensure audit-ready production.
✅ Full In-House Testing – Verification from prototype to SOP, ensuring reliability.
✅ Rapid Customization – Flexible designs, fast sampling, and quick validation cycles.
✅ One-Stop Solution – Connectors, cable assemblies, and harness integration under one roof.
✅ Competitive Value – Tier-one performance with optimized cost and local manufacturing support.

FPIC’s Vision: Reliable Connection for a Smarter, Greener Future

The connector industry is at the heart of every technological revolution — from electrification to intelligent mobility.
FPIC’s mission is to empower global customers with high-quality, innovative connector solutions that enable safer, cleaner, and smarter energy systems.

With over 20 years of precision manufacturing experience, FPIC continues to expand its role as a trusted global partner in the automotive and energy sectors — delivering connection technology that drives progress.

📩 Contact Us
For technical support or customized automotive connector solutions, please contact:
[email protected]
🌐 www.fpiconn.com