At Shenzhen Forman Precision Industry Co., Ltd. (Forman), building long-term partnerships with customers worldwide is at the heart of our business. A recent example is our ongoing cooperation with a valued customer from Russia, centered around the design and production of USB-A connectors.
Meeting Customer Needs with Customized USB-A Connectors
Several years ago, our Russian customer was searching for a stable, reliable, and high-quality USB-A connector solution for their products. Forman’s engineering team designed and delivered a customized USB-A connector that not only met the technical requirements but also offered:
✅ Stable electrical performance for long-term use
✅ Durable design suitable for demanding applications
✅ Compliance with international standards such as RoHS, REACH, and UL
✅ Cost-effective manufacturing with consistent quality
Our solution was quickly adopted, and since then, we have maintained a long-term and stable supply relationship for several consecutive years.
Customer Visit for New Project Development
Recently, the customer visited our headquarters in Shenzhen to review a new project under development. During the visit, they evaluated our R&D capabilities, laboratory facilities, and production lines.
They expressed high recognition of our:
Strong R&D and design capabilities for connector customization
Comprehensive quality and certification systems (ISO 9001, IATF 16949, ISO 14001, VDA 19.1)
Excellent business service and customer support throughout the collaboration
Building Trust Through Professionalism and Service
This visit further strengthened our partnership, with the customer expressing confidence in Forman’s ability to support both current and future projects. Our consistent delivery of quality products, professional engineering solutions, and responsive customer service has been the key to winning their trust and establishing long-term cooperation.
Looking Ahead
With this renewed cooperation, Forman is proud to continue supporting our Russian customer in USB-A connector solutions while expanding into new projects together. This case demonstrates our ability to combine engineering expertise, certified quality systems, and dedicated service to create value for customers worldwide.
At Shenzhen Forman Precision Industry Co., Ltd. (FPIC), we are proud to support global customers with high-performance connector solutions tailored to their industry needs. One of our recent success stories highlights the M12-M0282-0205-L3F circular connector, designed specifically for use in medical devices where safety, reliability, and durability are critical.
Meeting the Needs of Medical Device Applications
Medical equipment demands the highest standards of performance and compliance. Our customer required a secure, compact, and reliable M12 circular connector for their medical device to ensure accurate data transmission, stable signal performance, and ease of integration.
FPIC’s M12-M0282-0205-L3F connector was the ideal solution, offering:
? High reliability in signal transmission
? IP-rated protection for safety in sensitive environments
? Durability with long mating cycles for daily use
? Compact design suitable for medical equipment with limited installation space
Customer Visit & Positive Feedback
Recently, the customer visited FPIC to discuss project details and review our production capabilities. During the visit, they toured our R&D center, advanced testing laboratory, and automated assembly lines. They were highly impressed by our design expertise, engineering support, and quality assurance processes.
Upon reviewing our sample prototypes, the customer expressed great satisfaction with both the design solutions and product quality. They confirmed that they will place a long-term order with FPIC, strengthening our partnership and trust.
Building Long-Term Partnerships
At FPIC, we believe that every project is more than just a transaction—it is the foundation of a lasting partnership. This successful collaboration reflects our commitment to providing end-to-end solutions, from design and prototyping to mass production and testing.
We are honored to support our customer in the medical device industry and look forward to contributing to more healthcare innovations with our reliable connector technologies.
What Are the Applications for Push-Pull Self-Locking Connectors?
Push-pull self-locking connectors are compact, high-performance interconnect solutions known for their secure mating, quick-release mechanism, and excellent reliability in demanding environments. At Shenzhen Forman Precision Industry Co., Ltd. (FPIC), we specialize in manufacturing durable and customizable push-pull connectors widely used in critical industries.
1. Medical Equipment
One of the most prominent applications of push-pull connectors is in the medical industry, where precision and safety are paramount. These connectors are commonly used in:
Patient monitoring systems
Ultrasound and imaging devices
Dental equipment
Surgical instruments
Their compact design, secure locking mechanism, and high cycle durability (over 5000 mating cycles) make them ideal for life-critical applications.
2. Industrial Automation
In the industrial field, push-pull connectors are utilized in:
Sensor and actuator connections
Robotics
Test and measurement systems
Their quick-connect/disconnect feature significantly reduces maintenance time, while IP67 sealing and robust materials ensure resistance to vibration, dust, and moisture.
3. Automotive & Transportation
In the automotive sector, push-pull self-locking connectors support the increasing complexity of modern vehicles by enabling fast, reliable connections in:
Infotainment systems
Diagnostic tools
Electric vehicle battery monitoring systems
Their ability to withstand harsh conditions, including wide temperature ranges (-55°C to 250°C) and salt spray resistance up to 1000 hours, makes them perfect for in-vehicle and under-hood use.
4. Communication Systems
Push-pull connectors are widely used in broadcast and communication systems, particularly for:
Audio/video transmission
Base station equipment
Data networking
They ensure high-frequency signal integrity and secure connection in fast-paced environments.
5. Military and Aerospace
Push-pull connectors are also suitable for defense and aerospace systems due to their reliability under extreme conditions. Typical uses include:
Automated production ensures stable supply and high quality
Conclusion
Push-pull self-locking connectors are versatile, efficient, and built to last. Whether you are in medical, automotive, industrial, or communication sectors, FPIC’s customized solutions are designed to meet your unique connectivity needs.
? Contact us at [email protected] for samples or technical consultation.
Automotive connectors are the unsung heroes behind modern vehicle electronics. From lighting control to infotainment, these tiny components ensure secure signal and power transmission in environments that are anything but gentle. Moisture, vibration, high temperatures — and especially salt — are constant threats. That’s why the salt spray test is a vital benchmark in ensuring durability and long-term performance.
What Is a Salt Spray Test?
A salt spray test (or salt fog test) is a laboratory procedure used to evaluate the corrosion resistance of materials and coatings. Connectors are placed in a sealed chamber filled with a fine mist of 5% salt solution, replicating years of exposure to harsh environmental conditions like road salt, coastal air, and chemical spray — all common in real-world automotive scenarios.
This test runs for 48, 72, or even 96 hours, with results used to validate how well a connector can withstand corrosion without compromising its structural or electrical integrity.
A corroded pin or terminal increases electrical resistance, which leads to signal loss, power fluctuation, or complete failure. Salt spray testing ensures that your connectors will stay conductive and safe, even in salt-rich environments like snowy roads or coastal regions.
2. Protection for Critical Functions
Whether it’s lighting control, power seats, electric windows, or multimedia systems, FPIC automotive connectors are designed to maintain stable performance under extreme conditions. A failed connector in these systems could mean malfunctioning lights or unresponsive controls—and customer dissatisfaction.
3. EV-Ready and High-Voltage Capable
As new energy vehicles (NEVs) become mainstream, FPIC is also investing in the development of high-voltage automotive connectors. These require even higher resistance to corrosion, as failure in high-voltage components could compromise vehicle safety and efficiency.
Salt spray testing is an essential part of validating these next-gen products for long-term field use.
4. Meeting Global Automotive Standards
Passing salt spray tests is a requirement for many OEM and Tier 1 customers who demand compliance with IATF 16949 and other international quality standards. FPIC’s automotive connectors are tested to withstand up to 96 hours of salt spray, providing proven reliability and performance.
5. Confidence for Global Applications
From the icy roads of Scandinavia to the humid coasts of Southeast Asia, salt and corrosion vary by geography. By passing this test, FPIC connectors are validated for use in global automotive platforms, regardless of climate or terrain.
How FPIC Delivers Reliable, Corrosion-Resistant Connector Solutions
At FPIC, we provide complete connector solutions for:
Lighting systems (headlights, taillights, ambient lighting)
Seat control modules and heating units
Power window lift systems
In-car multimedia and infotainment applications
High-voltage connections for EV platforms
Our connectors are manufactured in fully automated production lines, with processes that include:
Terminal forming, bending, and riveting
Electrical performance testing
CCD vision inspection for size, alignment, and appearance
Tape & reel packaging for SMT-ready handling
Every product undergoes strict quality checks — and is backed by our zero-risk custom development promise, ensuring you receive a solution tailored to your needs without compromise.
Conclusion: Salt Spray Testing Is Not Optional — It’s Essential
The salt spray test may take place in a lab, but its impact is felt on every road, in every climate, and across every application. For FPIC, passing this test is not just about compliance — it’s about delivering automotive connectors that customers can trust in every condition.
When performance matters, and corrosion is the enemy, choose FPIC—where durability is engineered, tested, and proven.
https://fpiconn.com/wp-content/uploads/2025/07/salt-spray-test-machine-1.jpg500800fpiconnadministratorhttps://fpiconn.com/wp-content/uploads/2024/01/Logo-31.pngfpiconnadministrator2025-07-23 03:09:142025-10-23 04:35:36Why Salt Spray Test So Important for Automotive Connectors?
In the demanding world of automotive engineering, connector reliability is critical. Vehicles operate in harsh environments where temperature fluctuations, road salts, moisture, and chemical exposure can compromise connector performance over time. One of the most trusted indicators of corrosion resistance is the salt spray test—an essential part of automotive connector validation.
? What Is Salt Spray Testing?
Salt spray testing, also known as salt fog testing, is a standardized corrosion test used to evaluate the resistance of surface coatings to a saline environment. It simulates accelerated aging to predict how materials and coatings will perform in long-term real-world conditions.
The test exposes connectors or components to a continuous saline mist (typically 5% NaCl solution) inside a sealed chamber at 35°C (95°F). Components are evaluated over hours or days depending on the test standard and product requirements.
? Common Salt Spray Test Standards in the Automotive Industry
Automotive manufacturers follow strict standards to ensure product durability. Some of the most widely accepted test protocols include:
ISO 9227 (NSS Test) – Neutral salt spray, globally recognized.
ASTM B117 – Commonly used across industries for corrosion testing.
IEC 60068-2-11 – For environmental testing of electrical equipment.
JIS Z 2371 – Japanese industrial standard for salt spray resistance.
OEM-Specific Standards – Like VW PV1210, Ford CETP, or GM GMW 3172, which include extended test durations and failure criteria.
Automotive connectors are exposed to corrosive elements such as:
De-icing road salts
Humidity and water ingress
Engine fluids and chemicals
High-vibration environments
Corrosion can degrade conductivity, cause signal loss, increase contact resistance, and eventually lead to electrical failure. That’s why compliance with salt spray performance standards is crucial for any connector used in:
Powertrain systems
Battery electric vehicles (BEVs)
Energy storage modules
Sensor and control circuits
EV charging systems
? Forman’s Salt Spray Testing Capabilities
At Forman Precision Industry Co., Ltd., our automotive-grade connectors undergo rigorous in-house salt spray testing to ensure:
✅ 96 hours salt spray resistance under neutral conditions (NSS test) ✅ No visible corrosion or performance degradation ✅ Full compliance with IATF 16949 quality standards ✅ Corrosion-resistant coatings for long-term stability ✅ Application-specific design and prototyping support
? Our In-House Testing Laboratory
Equipped with environmental test chambers, our lab performs:
Salt spray & humidity testing
Thermal cycling & vibration analysis
Contact resistance & insulation testing
Cross-section analysis after exposure
Every production batch follows strict process control and traceability, ensuring product reliability from prototyping to mass production.
? Application Areas
Forman’s salt spray-tested connectors are ideal for:
✅ Over 20 years in precision connector manufacturing ✅ Certified: IATF 16949, ISO 9001, VDA 19.1, ISO 14001 ✅ Custom connector solutions from concept to production ✅ Fully equipped in-house testing for fast validation ✅ Trusted by global OEMs and Tier 1 suppliers
? Ready to Improve Your Connector Durability?
Partner with Forman to develop corrosion-resistant, automotive-grade connectors built to perform. ? Contact us at [email protected] ? Learn more: www.fpiconn.com
As the world transitions to a low-carbon future, energy storage systems (ESS) are becoming the cornerstone of modern power infrastructure. Whether supporting renewable energy, electric vehicles (EVs), or smart grids, the efficiency and reliability of these battery systems rely heavily on one often-overlooked component: the connector.
At Forman Precision Industry Co., Ltd (FPIC), we understand that high-performance energy storage connectors are not just accessories — they are essential to unlocking the full potential of battery technology. In this article, we explore the critical role that connectors play in advanced battery systems, the technologies behind them, and how we help customers deliver safer, smarter, and more efficient energy solutions.
Why Connectors Matter in Energy Storage Systems
Modern battery energy storage systems (BESS) must manage high voltage, high current, and intense thermal conditions — all while maintaining system integrity, safety, and longevity. The right energy storage connector:
Enables low-resistance power transmission
Ensures safe, secure connections under high voltage (often up to 1500V)
Simplifies maintenance and scalability
Supports modular battery pack design
Improves system uptime and reliability
Without high-quality, purpose-built connectors, energy storage systems risk voltage drops, heat generation, and even failure under dynamic operating conditions.
Key Types of Connectors in Battery Systems
? High-Voltage Battery Connectors
These are used in EV battery packs, grid-scale storage, and renewable energy systems. They’re engineered to support up to 1500V and currents from 100A to 350A or more, making contact resistance, insulation, and heat dissipation critical design considerations.
? Modular Energy Storage Connectors
Often used in lithium-ion battery modules and racks, these connectors allow for quick-disconnect, easy maintenance, and plug-and-play configurations — ideal for scalable ESS solutions.
? Power Connectors for Battery Management Systems (BMS)
These connectors provide signal and control data, ensuring real-time monitoring of battery temperature, voltage, and performance. They must offer stable contact, low noise, and shielding from electromagnetic interference.
Connector Design Factors that Influence Energy Storage Efficiency
✅ Current-Carrying Capacity
High-power energy storage connectors must be engineered for low contact resistance to avoid power loss and reduce heating, improving overall system efficiency and energy density.
✅ Thermal Management
Thermal buildup can damage batteries and reduce lifespan. Connectors designed with optimized conductor paths and heat-resistant materials improve safety and energy efficiency.
✅ Vibration & Shock Resistance
In mobile and industrial ESS applications, connectors must withstand mechanical stress, maintaining a secure connection without performance degradation.
✅ Ingress Protection (IP Ratings)
Connectors used in outdoor or industrial environments must meet IP67/IP68 standards, ensuring protection from dust, water, and contaminants.
✅ Material Quality
Premium copper alloys, gold-plated or silver-plated contacts, and high-performance thermoplastics are vital for corrosion resistance, conductivity, and long service life.
FPIC’s Energy Storage Connector Solutions
At FPIC, we deliver complete connector and cable assembly solutions designed specifically for battery storage and high-voltage applications.
? Custom Prototyping – Our engineering team works closely with clients to design and develop tailored connector solutions that match voltage, current, and installation needs. ? Cable Assembly Integration – We offer factory-assembled harnesses to reduce installation errors and support modular ESS deployment. ? In-House Testing – All products undergo stringent testing, including hipot testing, insulation resistance, salt spray, and temperature cycling, ensuring compliance with UL, TUV, and CE standards. ? Fast Sampling & Scalable Production – From pilot runs to mass manufacturing, FPIC supports your product launch and scale-up timelines.
Applications of Energy Storage Connectors
Our high-voltage energy storage connectors are widely used in:
Electric vehicle (EV) battery packs and charging stations
Uninterruptible power supplies (UPS)
Telecom power and industrial automation
End-to-End Value with FPIC
Choosing FPIC as your energy storage connector supplier means gaining a technology partner with deep experience in:
Connector R&D and precision manufacturing
Wire harness assembly and customization
System-level design support for modular battery applications
ISO 9001, ISO 14001, IATF 16949, and VDA 19.1 certified processes
We don’t just supply components — we build long-term connectivity solutions that drive performance, safety, and scalability.
Conclusion
As energy storage continues to evolve and expand, the demand for smarter, safer, and more efficient connectors will only grow. The right high-voltage connector improves thermal performance, simplifies integration, and enhances the overall reliability of battery systems.
At Forman (FPIC), we are committed to driving energy innovation forward — one powerful connection at a time.
As industries rapidly evolve towards electrification, renewable energy, and energy storage systems (ESS), the demand for high-voltage connectors with superior performance and uncompromised safety is higher than ever. At Forman Precision Industry Co., Ltd (Forman), we lead the way in high-voltage connector innovation, offering customers end-to-end solutions — from custom prototyping and sampling to full mass production, backed by our own in-house testing laboratory and assembly lines.
In this article, we explore the latest engineering innovations behind high-voltage connector design, and how Forman helps customers achieve better performance, greater safety, and faster time-to-market.
The Need for Innovation in High-Voltage Connectors
Modern energy systems — whether in electric vehicles (EVs), battery storage systems, industrial automation, or solar power plants — require connectors that:
Handle higher voltages and currents safely
Operate reliably in harsh environments
Offer easy installation and maintenance
Meet international safety and quality standards
To meet these growing demands, connector design must continually advance with new materials, smarter structures, and tighter manufacturing tolerances.
Mechanical robustness tests: Vibration, tensile strength, pull force tests
Environmental testing: Thermal cycling, salt spray, humidity resistance
Advanced color analysis and dimensional inspection for 100% quality assurance
Every Forman connector is rigorously tested to meet or exceed international standards before reaching our customers.
Applications We Support
? Energy Storage Systems (ESS) ? Electric Vehicles (EV) and Charging Stations ? Industrial Automation & Robotics ? Renewable Energy Plants (Solar, Wind) ? High-Performance Battery Packs
Why Partner with Forman for Your High-Voltage Connectivity Needs?
✅ 20+ Years of Expertise in precision metal and plastic parts manufacturing ✅ Certified Quality – IATF 16949, ISO 9001, ISO 14001, VDA 19.1, RoHS, REACH compliant ✅ Fast Turnaround from prototyping to mass production ✅ Customized, Scalable Solutions tailored to your project ✅ One-Stop Service – From design to testing to final product delivery
Conclusion
As industries continue to electrify and demand higher performance, innovative high-voltage connector design will be the cornerstone of safer, more reliable systems. At Forman, we are ready to engineer the future with you — delivering tested, proven, and customized connectivity solutions that empower your success.
? Ready to start your project? Contact us today at [email protected] — let’s innovate together! ?
As the demand for energy storage systems (ESS) grows rapidly across renewable energy, electric vehicles, and industrial sectors, the importance of reliable, high-performance connectors cannot be overstated. Energy storage connectors are critical to ensuring safe, efficient, and durable operation of these complex systems.
In this article, we’ll walk you through the best practices for selecting and installing energy storage connectors to help maximize system performance and longevity.
1. Understand Your Application Requirements
Before selecting a connector, you must clearly define the operational conditions and performance needs of your energy storage system.
? Voltage and Current Ratings Choose connectors that can handle the system’s maximum voltage and current levels without overheating or degradation. For instance, in large battery packs, you may need 1500V high-voltage connectors capable of managing hundreds of amperes safely.
Look for connectors with IP67/IP68 ratings and corrosion-resistant materials for outdoor or industrial settings.
? Standards and Certifications Ensure connectors comply with relevant standards such as UL, TUV, CE, and RoHS for quality, safety, and environmental protection.
? High Voltage Energy Storage Connectors Designed for large ESS systems, capable of handling high power safely and efficiently.
? Battery Storage Connectors Specially built for modular battery pack connections, ensuring low resistance and secure locking mechanisms.
? Power Connectors for Batteries Robust designs that handle high currents with minimal heat generation and maximum efficiency.
Tip: Always consider using shielded connectors in environments where electromagnetic interference (EMI) may be a concern.
3. Pay Attention to Connector Materials
Material selection impacts the performance, safety, and durability of connectors:
✅ Contact Materials: Look for connectors with silver or gold-plated contacts to enhance conductivity and prevent corrosion. ✅ Housing Materials: Choose housings made of high-grade plastics or thermoset composites for mechanical strength and thermal resistance. ✅ Sealing Materials: Ensure sealing materials are compatible with operating temperatures and chemical exposure.
4. Best Practices for Installing Energy Storage Connectors
Proper installation is just as crucial as selecting the right connector:
? Follow Manufacturer Guidelines Always refer to the manufacturer’s installation instructions to prevent damaging the connectors or compromising system performance.
? Secure Connections Use proper torque specifications when tightening connectors to ensure solid, vibration-resistant electrical contact. Avoid over-tightening, which could crack housings or damage contacts.
? Inspect and Clean Mating Surfaces Before mating, clean connectors thoroughly to remove dust, oils, or debris that could affect conductivity or sealing.
? Use Appropriate Tools Employ recommended crimping, assembly, and installation tools to achieve proper fits and to avoid physical stress on cables and terminals.
? Double-Check Polarity and Wiring Incorrect wiring can cause system failures or safety hazards. Always double-check wiring diagrams and polarity before final installation.
5. Plan for Maintenance and Serviceability
When designing your energy storage system, choose connectors that allow easy access for maintenance, replacement, and upgrades. Quick-connect/disconnect features can significantly reduce downtime during servicing.
Regular inspections should include:
Checking for signs of wear, corrosion, or overheating
Verifying locking mechanisms remain secure
Testing for electrical continuity and insulation integrity
Conclusion
Selecting and installing the right energy storage connectors is critical to ensuring the safety, efficiency, and longevity of modern energy systems. By following these best practices, manufacturers, integrators, and system designers can deliver more reliable and cost-effective energy storage solutions.
At Forman (FPIC), we specialize in high-voltage connectors, battery storage connectors, and customized energy storage solutions designed to meet the most demanding industrial and renewable energy applications.
https://fpiconn.com/wp-content/uploads/2025/04/energy-storage-connector-application.jpg500800fpiconnadministratorhttps://fpiconn.com/wp-content/uploads/2024/01/Logo-31.pngfpiconnadministrator2025-04-28 08:10:322025-10-23 04:37:19Best Practices for Selecting and Installing Energy Storage Connectors
Metal stamping molds are essential in manufacturing industries, enabling precise and efficient production of metal components. The mold assembly process plays a critical role in ensuring the quality, durability, and accuracy of stamped parts.
In this article, we will walk you through the complete metal stamping mold assembly process, covering essential steps, best practices, and quality control measures. Whether you are a mold engineer, manufacturer, or industry professional, this guide will provide valuable insights into achieving high-performance stamping molds.
I. Pre-Assembly Preparation
Before starting the assembly process, it is crucial to prepare the necessary tools, measuring instruments, and reference documents to ensure smooth execution.
1. Tools & Measuring Instruments
Ensure that the required tools and measuring instruments are available, including:
Familiarize yourself with the entire mold assembly process:
Main Plate Gluing(Clamping Plate + Stripper Plate + Bottom Plate)
Template Assembly
Clamping Plate Component Assembly
Stripper Plate Assembly
Bottom Plate Assembly
Upper & Lower Mold Matching & Confirmation
Mold Base Gluing(Upper & Lower Mold Base)
Installation of Standard Components
Trial Stamping & Sample Testing
II. Template & Component Inspection Before Assembly
1. Template Inspection
✅ Material & Hardness Verification: Ensure templates have undergone deep-freezing and stabilization treatment. ✅ Flatness & Warping Check: Warping should not exceed 0.005mm per 100mm. ✅ Hole Position & Processing Accuracy: Verify drilled holes, allowances, and surface finish. ✅ Screw Hole Depth & Alignment: Check threaded hole depth and perpendicularity for proper fastener fitment. ✅ Embossing & Pressing Grooves: Ensure correct width and depth. ✅ Labeling & Marking: Verify mold number, material width, pitch, and part name.
2. Component Inspection
Material, Quantity & Hardness Verification
Dimensional Accuracy Check
Proper inspection eliminates potential errors that could cause misalignment, improper fits, and structural weaknesses in the final mold.
III. Template Machining & Finishing
1. Mold Base Preparation
Clean all threaded holes of debris; check for damaged or unthreaded holes.
Deburr sharp edges and corners using a flat file.
Polish the surface with an oil stone to remove burrs.
2. Hole Deburring & Edge Rounding
Use round oil stones, files, grinders, and sandpaper for chamfering insert holes, round holes, and square holes.
Remove oxidation residues from wire-cut holes using fiber oil stones and round rods.
3. Surface Finishing
Polish the template with fine oil stones in the direction of the grinding pattern.
Use lubricating oil during polishing to prevent scratches.
4. Demagnetization
Use a demagnetizer to remove magnetism from the mold base and all components to prevent iron powder absorption, which could affect assembly accuracy.
5. Cleaning
Clean templates thoroughly using mold cleaner and compressed air.
Precision mold assembly requires a high level of cleanliness to ensure optimal performance.
6. Component Handling
Engrave part numbers on components.
Add lead-in angles to guide posts.
Sort, match, and demagnetize all parts.
Tip: Precision molds require extreme cleanliness to prevent defects in stamped parts.
IV. Measurement & Alignment Verification
1. Template Parallelism Measurement
Fix a dial indicator to zero on a reference platform and measure.
Standard tolerance: ≤ 0.002mm.
2. Template Warping & Deformation Check
Press one end of the template and observe dial indicator changes at the other end.
Deformation should not exceed 0.003mm.
3. Main Template Parallelism & Warping Measurement
Tolerance should not exceed 0.005mm.
4. Guide Post & Guide Bushing Measurement
Ensure guide posts conform to the required dimensions and roundness.
Measure guide post fitment and machining accuracy per the drawings.
V. Mold Gluing Process
1. Gluing Steps
Step 1:
Use 0.005mm shims to check for gaps after mold closure.
The mold is qualified when shims cannot enter the gap.
Step 2:
After confirming the main template, insert a 10mm positioning pin from the clamping plate to the bottom plate to align the three primary templates.
If any gaps exist, check for debris or interference before proceeding.
Step 3:
Clean guide post and guide bushing thoroughly.
Insert guide posts into the stripper plate and secure with screws.
Place 0.2mm steel shims in each guide bushing hole.
Step 4:
Apply 680 glue evenly on the guide bushings while rotating them for even distribution.
Slowly insert guide bushings into the template until they rest against the steel shims.
Repeat for all guide bushings.
VI. Standard Component Assembly
1. Standard Component Inspection
Verify that all standard parts meet specifications.
2. Height & Position Check
Confirm the heights of floating pins, equal-height sleeves, limit posts, guide pins, and ejector rods.
3. Standard Component Installation
Clean all round holes before inserting components.
Install components into the mold cavity in order.
4. Final Confirmation
Ensure all parts are flat and properly fitted.
Verify free movement of standard components.
Check for clogged scrap ejection holes.
Ensure adjustment rods are correctly positioned and do not interfere with other templates.
VII. Mold Testing & Issue Documentation
1. Mold Closure Height Verification
Record closure height in the Mold Testing & Issue Report.
2. Manual Mold Closure Test
Close the mold manually to check for proper spring compression.
3. Trial Stamping & Sample Testing
Record initial data for comparison in subsequent trials.
Repeat trials until samples meet specifications.
4. Issue Analysis & Data Collection
Document all design & machining issues.
Analyze the root cause and record corrective actions.
Collect data for future design optimizations.
Example: Mold Testing & Issue Report
Date
Issue Description
Corrective Action
Design Issue
Machining Issue
Resolution Date
Result
Responsible Person
2.18
Tight-fitting D07 forming part
Wire-cut rework
✔
2.18
Normal
Engineer A
2.19
S05 part causing ejection failure
Added ejector structure
✔
2.19
Normal
Engineer B
2.19
Dimension 2.02mm undersized
Added 0.02mm shim
✔
2.19
Normal
Engineer B
2.20
Sent for FAI inspection
2.20
QA Inspector
Note: All mold trials must be fully documented, ensuring a complete history of deviations and corrective actions.
Conclusion
The metal stamping mold assembly process requires precision, attention to detail, and strict quality control to ensure high-performance and long-lasting molds. By following these structured steps—from pre-assembly preparation to final testing—manufacturers can optimize efficiency, reduce downtime, and improve mold longevity.
Implementing these best practices will help ensure high-quality stamped parts, reducing waste, rework, and production costs.
At FPIC, we specialize in precision mold manufacturing with a focus on quality, efficiency, and innovation. Contact us today to learn more about our custom mold solutions!
https://fpiconn.com/wp-content/uploads/2025/03/metal-mold-assembly.jpg500800fpiconnadministratorhttps://fpiconn.com/wp-content/uploads/2024/01/Logo-31.pngfpiconnadministrator2025-03-27 06:33:032025-03-27 06:54:15Comprehensive Guide to Metal Stamping Mold Assembly
Selecting the right fluid connector is crucial for ensuring efficient, safe, and leak-free fluid transfer in industrial applications. Whether used in automotive, aerospace, medical, or industrial automation, the wrong connector can lead to system failures, leaks, and costly downtime.
At Shenzhen Forman Precision Industry Co., LTD (Forman), we specialize in high-performance fluid connectors designed to meet demanding industry requirements. In this guide, we’ll explore the key factors to consider when choosing a fluid connector to ensure optimal performance and reliability.
1. Understand Your Application Needs
Before selecting a fluid connector, it’s important to analyze your specific application requirements, including:
✔️ Type of Fluid – Is the system handling water, oil, chemicals, hydraulic fluid, or gas? The material and sealing must be compatible with the fluid. ✔️ Operating Pressure & Temperature – Choose a connector that can withstand high or low pressures and extreme temperatures. ✔️ Environmental Conditions – Will the connector be exposed to corrosion, moisture, dust, or vibration? ✔️ Connection & Disconnection Frequency – If frequent changes are required, a quick-connect push-pull mechanism can improve efficiency.
By understanding your specific use case, you can ensure your fluid connector meets performance, safety, and durability standards.
2. Consider the Material & Durability
The material of a fluid connector affects its strength, resistance, and longevity. Common options include:
? Stainless Steel – Highly corrosion-resistant, ideal for harsh environments, chemical exposure, and high temperatures. ? Aluminum – Lightweight and durable, often used in aerospace and automotive applications. ? Brass – Good for general industrial applications, offering a balance of durability and cost-effectiveness. ? Plastic & Composite Materials – Suitable for low-pressure applications, lightweight, and resistant to chemicals.
At Forman, our stainless steel connectors are built for maximum durability and corrosion resistance, ensuring long service life in demanding environments.
3. Choose the Right Locking & Connection Type
Different applications require different locking mechanisms to ensure secure and reliable fluid transfer. The most common types include:
✔️ Push-Pull Self-Locking Connectors – Quick, one-handed connection and disconnection, perfect for frequent use and fast assembly. ✔️ Threaded Connectors – Secure, high-pressure connections that require tightening but provide strong sealing. ✔️ Bayonet Coupling – Twist-lock connectors that ensure vibration resistance in high-movement applications. ✔️ Snap-On & Quick-Release Couplings – Designed for fast maintenance and tool-free assembly.
For industrial automation, medical devices, and fluid cooling systems, push-pull locking connectors offer ease of use, safety, and efficiency.
4. Ensure Leak-Proof & High-Sealing Performance
A leak-proof seal is essential for fluid efficiency, safety, and system reliability. The right sealing material should match your application’s fluid type and operating conditions.
? O-Ring & Gasket Seals – Prevent leaks and are available in various materials (NBR, EPDM, PTFE, Viton) depending on fluid compatibility. ? Metal-to-Metal Sealing – Common in high-pressure hydraulic and gas systems, providing excellent durability. ? Multi-Layer Seals – Used for extreme environments where temperature or pressure fluctuations are significant.
At Forman, our fluid connectors feature advanced sealing technology to prevent leaks even under high pressure and temperature fluctuations.
5. Verify Industry Standards & Certifications
When selecting a fluid connector, ensure it meets industry standards to guarantee quality, performance, and safety compliance. Key certifications include:
✅ VDA 19.1 & ISO 16232-10 – Ensuring technical cleanliness for automotive and industrial applications. ✅ IATF 16949 – Quality management standard for automotive manufacturing. ✅ ISO 9001 – General quality assurance for consistent manufacturing. ✅ IP67/IP68 Waterproof Ratings – Protection against dust and water ingress.
At Forman, we manufacture fully compliant fluid connectors to meet the highest industry standards for cleanliness, durability, and safety.
6. Select the Right Connector Size & Flow Capacity
Fluid connectors must match the flow rate and system size to avoid pressure loss or restricted flow.
✔️ Hose & Port Compatibility – Ensure that the connector size matches the hose diameter and system fittings. ✔️ Flow Rate Requirements – Larger connectors allow higher fluid flow, while smaller ones are optimized for precision fluid transfer. ✔️ Pressure Drop Considerations – Selecting the correct connector bore size prevents energy loss and system inefficiency.
Forman provides customized fluid connectors to ensure perfect compatibility with your system specifications.
At Forman, we design fluid connectors for quick installation, reducing labor time and improving overall efficiency.
Why Choose Forman’s Fluid Connectors?
At Forman, we provide precision-engineered fluid connectors designed for leak-proof, durable, and efficient performance in industrial applications. Our solutions offer:
✔️ High-quality stainless steel & aluminum construction for durability. ✔️ Advanced sealing technology for leak-proof connections. ✔️ Push-pull quick-locking mechanisms for ease of use. ✔️ Custom solutions to meet industry-specific requirements. ✔️ Certified manufacturing (ISO 9001, IATF 16949, VDA 19.1) ensuring global compliance.
? Looking for the perfect fluid connector for your system? Forman has the solution! ?
Choosing the right fluid connector ensures efficient, leak-free, and long-lasting fluid transfer in industrial applications. By considering fluid compatibility, pressure requirements, locking mechanisms, sealing technology, and industry standards, you can select a connector that enhances performance and reliability.
At Forman, we are committed to delivering high-quality fluid connector solutions that meet the highest performance, cleanliness, and safety standards.
? Upgrade your fluid transfer systems today with Forman’s premium fluid connectors!
https://fpiconn.com/wp-content/uploads/2025/03/Fluid-Connectors.jpg500800fpiconnadministratorhttps://fpiconn.com/wp-content/uploads/2024/01/Logo-31.pngfpiconnadministrator2025-03-15 09:06:092025-03-15 09:06:09How to Choose the Right Fluid Connector – A Complete Guide
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VI. Standard Component Assembly
