R&D Capability

Engineering Support from Concept to Mass Production

Need a connector supplier who can support more than standard product delivery? FPIC provides engineering and R&D support for custom connector, cable assembly, terminal, plastic part, and metal component projects.

From requirement review, product design, material selection, CAE simulation, prototype validation, laboratory testing, tooling coordination, and trial production to mass production transfer, FPIC helps customers reduce development risk and build reliable connector solutions for real applications.

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What Makes FPIC R&D Different?

FPIC is not only a connector manufacturer. Our R&D team works directly with tooling, plastic injection, metal processing, assembly, wire harness production, quality control, purchasing, PMC, and sales teams. This cross-functional structure allows us to evaluate product feasibility, manufacturing risk, testing requirements, and production stability at an early stage.

For customers, this means one engineering team can help connect the full development chain: design review, prototype, validation, tooling, product in process, inspection, and delivery.

FPIC R&D Supports

Drawing-based and sample-based product development
OEM and ODM connector projects
Product replacement and localization solutions
Product structure optimization
Material selection and technical evaluation
CAE simulation and design verification
Prototype development and sample validation
Tooling coordination and mold trial support
Laboratory testing during product development
Trial production and mass production transfer
Cost reduction and manufacturability improvement

R&D Capability at a Glance

Note: Actual development schedule and validation scope may vary depending on product complexity, tooling requirements, testing standards, customer approval process, and mass production requirements.

Capability Area	FPIC Support
Product Development	Custom connector development, replacement development, structure optimization, precision component design
Design Tools	CREO, ANSYS, ZW CAD and related CAD/CAE tools
Digital Systems	PLM, MES and ERP support for engineering data, process coordination and production traceability
Development Cycle	Consumer connector development can be completed in about 35 days; automotive product development usually takes about 60 days, depending on product complexity
Product Precision	Product precision can reach 0.01 mm depending on product structure, material and process requirements
Process Control	CPK ≥ 1.33 and PPK ≥ 1.67 can be applied according to customer project requirements
Project Capacity	Around 6 development projects per month, depending on project difficulty and resource allocation
Standards Reference	LV214, LV215, USCAR 2, USCAR 38, EIA, GB and VDA 6.3 references can be considered based on application and customer requirements

R&D Development Process

FPIC follows a structured engineering process to help customers move from idea, drawing, sample, or replacement requirement to validated production.

1. Requirement Review
FPIC reviews customer drawings, 3D files, samples, specifications, application conditions, rated voltage, rated current, mechanical requirements, environmental requirements, annual demand, target cost, and delivery expectations.
2. Technical Feasibility Analysis
Our engineering team evaluates product structure, material options, tooling feasibility, process risks, test requirements, assembly method, cost targets, and mass production possibility before development starts.
3. Product Design and Structure Optimization
FPIC supports 2D and 3D design review, connector housing design, terminal matching, locking structure optimization, sealing structure review, anti-misplug design, and assembly feasibility improvement.
4. Material Selection
Material selection is evaluated according to electrical performance, mechanical strength, temperature resistance, flame retardancy, corrosion resistance, mating cycles, sealing requirements, and application environment.

5. Prototype Development
FPIC can support prototype development based on customer drawings, samples, functional requirements, or replacement targets. Prototype review helps identify design, structure, material, and assembly risks before mass production.
6. Tooling Coordination and Mold Trial
R&D works with tooling and production teams to support mold development, mold trial, sample inspection, tooling improvement, and design adjustment.
7. Development Validation and Laboratory Testing
During development, FPIC’s in-house laboratory supports electrical, mechanical, environmental, dimensional, material, plating, X-ray, temperature rise, bending, and cleanliness-related verification according to project requirements.
8. Trial Production and Mass Production Transfer
After sample approval, FPIC supports trial production, process confirmation, inspection planning, production documentation, quality control setup, and transfer to stable mass manufacturing.

CAE Simulation and Engineering Verification

FPIC uses CAE simulation and design verification to improve product reliability before tooling and mass production. Simulation helps the engineering team identify potential design risks earlier and optimize structure, tooling, and electrical performance.

Product Design and Tooling Development

Our engineering team supports product structure design together with tooling development, helping improve manufacturability and shorten the development cycle from concept to production.

Structural Simulation

Structural simulation helps evaluate housing strength, terminal contact structure, spring behavior, locking design, mechanical stability, and product reliability under application conditions.

Mold Flow Simulation

Mold flow analysis supports resin filling evaluation, shrinkage control, tooling optimization, and manufacturability improvement for precision connector plastic parts.

Current Rating Simulation

Current rating simulation helps assess current-carrying behavior, heat generation risk, and performance stability for power connectors, energy storage connectors, automotive connectors, and other high-current applications.

Material Engineering Support

A connector’s reliability depends heavily on material selection. FPIC evaluates plastic, metal, plating, and sealing materials according to product function, application environment, reliability requirements, and customer specifications.

Plastic Materials

FPIC can evaluate and apply engineering plastics such as LCP, PBT, PA6T, PA9T, PA10T, PA66, PVC and TPU according to project requirements.

Metal Materials

FPIC supports material evaluation for terminals, pins, sockets, shielding parts and precision components, including C1100, C2600, C2680, C3604, C54400, C5191, C5210, C7025, C7035, C18400, SUS301, SUS304 and SPCC.

Plating Options

Plating options may include gold, silver, nickel and tin, depending on conductivity, corrosion resistance, mating cycles, contact performance, and application requirements.

Sealing Materials

For sealed connector designs, FPIC can evaluate rubber, FKM and silicone materials according to waterproof, sealing, temperature, and environmental requirements.

Development Validation & In-House Testing Lab Support

Testing is an important part of FPIC’s R&D process. During product development, our in-house laboratory helps engineering and quality teams verify whether the design, material, structure, and performance meet project requirements before mass production.

In the R&D stage, testing is used to support design verification, prototype validation, material evaluation, temperature rise analysis, structural reliability review, and production risk reduction.

Electrical Performance Testing

FPIC can verify conductivity, current-carrying performance, withstand voltage, insulation performance, contact resistance, and temperature rise for connector and cable assembly projects.

Wire Comprehensive Tester

Withstand Voltage & Insulation Tester (10000V)

USB Temperature Rise Tester (MAX 800W)

Energy Storage Temperature Rise Tester (1000A)

Contact Impedance Tester

Dimensional and Structural Verification

Dimensional consistency and internal structure quality are essential for reliable manufacturing and assembly. FPIC uses KEYENCE one-click measurement equipment for programmable dimensional testing and X-ray inspection equipment for internal structure analysis. These tools help verify dimensional accuracy, assembly condition, and internal product integrity more efficiently.

Microscope

Vickers Microhardness Tester

Pre-Polishing Machine

2D Coordinate Measuring Machine

Keyence One-button Measuring Machine

Environmental and Material Testing

FPIC’s laboratory supports environmental validation through thermal shock testing, high-temperature reflow soldering evaluation, horizontal and vertical flammability testing, and related reliability checks. These tests help assess product stability under temperature variation, heat exposure, and material performance requirements in demanding applications.

High-temperature Oven

Constant Temperature and Humidity Test Chamber

Three-zone Thermal Shock Test Chamber

X-ray Spectrometer

X-ray Fluoroscope

Mechanical Reliability Testing

Mechanical testing helps verify insertion and withdrawal force, cable durability, drop resistance, vibration resistance, and overall structural performance during use and transportation. FPIC uses insertion force testing equipment, wire bending test equipment, drop testing equipment, and transportation vibration testing equipment to evaluate connector and harness durability under realistic handling and operating conditions.

Fully Automatic Insertion and Extraction Force Tester

Fluorescent Coating Thickness Gauge

360° Wire Bending Tester

Servo Tensile Testing Machine

Horizontal & Vertical Flammability Tester

Plating and Internal Quality Analysis

FPIC also uses a fluorescence coating thickness gauge and X-ray spectrometer to support plating thickness verification and material-related analysis. Together with X-ray fluoroscopy equipment and high-cleanliness inspection equipment, these tools improve our ability to evaluate product quality from both external and internal perspectives.

High-Cleanliness Inspection Capability

For products requiring better contamination control and stricter quality standards, FPIC is equipped with high-cleanliness inspection equipment to help verify product cleanliness and support more stable manufacturing quality. This capability is especially valuable for applications requiring stronger control over foreign particles and assembly cleanliness.

Product Development Experience

FPIC’s R&D team supports product development across multiple connector and component categories. Our engineering experience covers automotive connectors, energy storage connectors, circular connectors, push-pull self-locking connectors, PCB connectors, fluid connectors, wire harnesses, terminals, plastic parts, and metal parts.

Typical Development Projects

Automotive window control connectors
USB Type-C connectors
M series circular connectors
Push-pull self-locking circular connectors
Fluid connectors
Liquid cooling connector solutions
Customized connector and component projects based on drawings or samples

Application-Oriented Development

FPIC develops connector solutions based on real application requirements, including automotive modules, energy storage systems, industrial automation equipment, medical equipment, e-motorcycle systems, solar applications, and precision electronic devices.

Patents and Technical Strength

FPIC continues to invest in product innovation and engineering capability to support long-term technology development.

These technical assets support FPIC’s ability to develop differentiated products, optimize existing solutions, and provide engineering support for customized customer projects.

Innovation Highlights

Utility Patents

Appearance Patents

Invention Patents

FPIC

Own Brand

From R&D to Scalable Manufacturing

FPIC’s R&D work is closely connected with in-house manufacturing resources. Engineering decisions are coordinated with tooling, plastic injection, metal processing, assembly, wire harness production, testing, quality control, purchasing, PMC, and sales teams.

This helps customers reduce communication cost, solve manufacturing risks earlier, improve development efficiency, and move more smoothly from prototype to mass production.

Cross-Functional Support Includes

Tooling feasibility review
Plastic part manufacturability evaluation
Metal terminal and contact structure review
Assembly process review
Testing and validation planning
Material and supplier coordination
Trial production support
Quality control planning
Production process standardization
Mass production transfer

Submit Your Project Requirements

What We Need for Engineering Evaluation

In addition to standard products, FPIC supports custom connector and precision component development for OEM and project-based applications.

Submit Your Project Requirements

To provide faster and more accurate engineering support, customers are encouraged to share the following information:

Product drawing, 3D file, datasheet, or sample
Application industry and installation position
Rated voltage and rated current
Pin count, pitch, mating type, and locking structure
Material, plating, sealing, and flame-retardant requirements
Temperature, waterproof, vibration, salt spray, or bending requirements
Required certifications or testing standards
Sample quantity and annual demand
Target delivery schedule
Current supplier reference or replacement target, if available

Why Customers Choose FPIC for Connector R&D

FPIC combines engineering support, integrated production capability, and validation-oriented development to help customers move projects forward with more confidence and efficiency.

Manufacturable Engineering Solutions

FPIC focuses on engineering solutions that can be transferred into production, not only design concepts. Our R&D team evaluates product feasibility together with tooling, production, and quality teams.

Integrated Development and Manufacturing

With in-house support for tooling, injection molding, metal processing, connector assembly, wire harness production, and testing, FPIC can improve development coordination and reduce project communication costs.

Validation-Oriented Development

Simulation, prototype review, sample validation, inspection, and laboratory testing help identify risks before mass production.

Smooth Mass Production Transfer

Engineering decisions are aligned with production process, inspection planning, and quality control requirements, helping improve product consistency and delivery stability.

FAQ

Can FPIC develop custom connectors based on customer drawings or samples?

Yes. FPIC can support drawing-based development, sample-based replacement, OEM/ODM projects, and customized connector development according to customer application requirements.

What information is needed for a new connector development project?

Customers are encouraged to provide drawings, 3D files, samples, application details, electrical requirements, mechanical requirements, environmental requirements, testing standards, quantity forecast and delivery expectations.

How long does custom connector development usually take?

The development cycle depends on product complexity and testing requirements. Consumer connector development can be completed in about 35 days, while automotive product development usually takes about 60 days. More complex customized or high-reliability projects may require a longer schedule.

Can FPIC support material selection?

Yes. FPIC can evaluate plastic materials, metal materials, plating options and sealing materials based on electrical performance, mechanical strength, temperature resistance, corrosion resistance, sealing requirements and customer application conditions.

Does FPIC support CAE simulation?

Yes. FPIC uses CAE simulation and design tools to support structural analysis, mold flow evaluation and current-carrying performance review during product development.

Can FPIC support automotive connector development?

Yes. FPIC can support automotive connector projects based on customer requirements and applicable references such as LV214, LV215, USCAR 2, USCAR 38, EIA, GB and VDA 6.3.

Does FPIC have in-house testing support during product development?

Yes. FPIC’s in-house laboratory supports development validation through electrical, mechanical, environmental, dimensional, material, plating, X-ray and cleanliness-related checks according to project requirements.

Can FPIC support mold trial and sample validation?

Yes. FPIC’s R&D team works with tooling, production, and quality teams to support mold trial, sample inspection, tooling adjustment, sample validation, and production transfer.

Can FPIC help optimize an existing product?

Yes. FPIC can support product structure optimization, material improvement, cost reduction, manufacturing efficiency improvement, and replacement development according to customer project goals.

Can FPIC support mass production after prototype approval?

Yes. After sample approval, FPIC can support trial production, process confirmation, quality control planning, production documentation, and mass production transfer.

Talk to Our Engineering Team

Looking for technical support for a connector or precision component project? FPIC can support: concept review, CAE-assisted development, tooling coordination, laboratory validation, OEM/ODM engineering support.