Press-Fit Terminals: The Zero-Solder Solution Securing EV Battery Safety
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:
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Insertion & extraction force validation
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Thermal cycling and vibration endurance
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Temperature rise testing
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Corrosion resistance & salt spray testing
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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
