Connector Contact Pin & Socket, Blog

Connector Contact Manufacturing: From Brass Rod to Finished Pin

Posted on by Franky Nguyen

By Franky Nguyen, AVF Decolletage

Introduction

Connector contact manufacturing is a precise and complex process. These small pins may look simple, yet they are vital for transferring power and data in aerospace, automotive, medical, and telecom systems. Without them, modern electronics would not function.

At AVF Decolletage, we transform raw brass rods into finished connector pins with Swiss CNC and CAM machining. Each step—from material selection to plating and final inspection—is carefully controlled under ISO 9001:2015 standards.

In this blog, we’ll take you inside the full journey: how brass rods become high-performance connector contacts used by global OEMs.

Step 1: Selecting the Right Material

Connector performance begins with the material. Brass is the most widely used choice because it combines conductivity, machinability, and durability. At AVF Decolletage, we use only certified alloys, such as:

  • C36000 Free-Cutting Brass – excellent machinability, widely used for general-purpose connectors.

  • C17300 Beryllium Copper (BeCu) – higher strength and elasticity, great for spring-loaded contacts.

  • C54400 Phosphor Bronze – enhanced wear resistance, suitable for high-cycle applications.

  • C19160 (C97) and C18700 (C99) – specialized alloys for high-reliability connectors.

Each alloy is chosen based on the customer’s application—whether it’s conductivity for telecom, strength for automotive, or corrosion resistance for aerospace.

See our full material list.

Step 2: Cutting and Preparing Brass Rods

The process begins with solid brass rods, sourced in bulk. These rods are cut into precise lengths to fit into Swiss CNC and CAM machines.

Consistency at this stage is critical. If rods are not cut evenly, the machining process can suffer from vibration, tool wear, or misalignment. At AVF Decolletage, every rod is inspected for diameter and straightness before entering production.

Step 3: Swiss Machining the Connector Pins

Connector contact female socket by AVF Decolletage, precision CNC machined for electronic and aerospace applications.
High-precision female socket contact manufactured by AVF Decolletage, ensuring reliable connectivity in electronic and aerospace connectors.

This is where the raw rod becomes a connector pin. Swiss CNC and CAM lathes perform multiple operations in a single cycle, including:

  • Turning – reduces the rod to the exact pin diameter.

  • Drilling – creates recesses or holes for sockets.

  • Milling – adds slots or flats for orientation.

  • Threading – where fastening features are needed.

With over 350 Swiss lathes (Bechler, Tornos, Star, Tsugami, Cincom), AVF Decolletage achieves tolerances as tight as ±0.005 mm, ensuring each pin is consistent across millions of parts.

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Step 4: Secondary Operations

After initial machining, pins often undergo secondary processes:

  • Zone Annealing – selectively softens certain sections for bending or forming.

  • Heat Treatment – improves hardness and mechanical strength.

  • Centerless Grinding – ensures perfectly round diameters for smooth fits.

  • Polishing and Deburring – removes sharp edges and ensures burr-free finishes.

These steps make pins safer to use, easier to assemble, and more durable under stress.

Step 5: Plating for Enhanced Performance

Although brass is conductive, most connector pins require plating to extend performance. Common choices include:

  • Gold Plating – best for conductivity, corrosion resistance, and low contact resistance.

  • Nickel Plating – adds hardness and protects against wear.

  • Tin Plating – economical choice, great for soldering applications.

Plating thickness is carefully controlled to balance cost and durability. In high-reliability applications like aerospace or defense, gold is often required despite its cost.

Learn about our quality system.

Step 6: Quality Control and Inspection

Every batch undergoes strict ISO 9001:2015-certified inspection. Key checks include:

  • Dimensional Accuracy – measured with Mitutoyo calipers, CMMs, and microscopes.

  • Plating Thickness – verified using X-ray fluorescence (XRF) technology.

  • Electrical Resistance Testing – ensures low and stable contact resistance.

  • Batch Traceability – each lot is fully documented.

See our ISO certification.

Step 7: Packaging and Delivery

Once approved, connector pins are ultrasonically cleaned, packaged, and labeled with full documentation. This guarantees they arrive ready for automated assembly lines at global OEM facilities.

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Applications of Brass Connector Contacts

Connector pins manufactured from brass are found in nearly every industry:

  • Aerospace – avionics systems, sensors, and in-flight electronics.

  • Automotive – ECU connectors, EV charging systems, and safety sensors.

  • Medical Devices – surgical instruments, diagnostic tools, and implants.

  • Telecommunications – fiber optic connectors, 5G modules, and RF systems.

  • Industrial Automation – robotics and smart manufacturing systems.

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Challenges in Connector Contact Manufacturing

While the process is refined, it still presents challenges:

  • Maintaining Tight Tolerances – solved with Swiss CNC precision.

  • Surface Quality – addressed through polishing and burr-free machining.

  • Plating Consistency – managed with automated plating lines.

  • Material Variation – reduced by sourcing certified rods with full material certifications.

Check material certification samples.

Case Studies

Automotive EV Charging Pins

A leading EV manufacturer required high-current connector pins for charging stations. The challenge was conductivity with vibration durability.

  • Solution: AVF Decolletage selected C17300 BeCu alloy with gold plating.

  • Result: Pins passed 10,000+ mating cycles without failure.

Aerospace Avionics

An aerospace customer needed connectors resistant to extreme vibration and temperature swings.

  • Solution: Pins were machined from C54400 phosphor bronze and nickel plated.

  • Result: Long service life under harsh conditions.

Future of Connector Contact Manufacturing

The industry continues to evolve. Trends include:

  • Miniaturization – smaller pins for IoT and wearables.

  • High-current designs – critical for EV and renewable energy.

  • High-frequency applications – low-loss connectors for 5G and beyond.

  • Automation & AI – smarter QC systems using AI-driven vision inspection.

  • Sustainability – lead-free plating, recyclable alloys, and eco-friendly production.

AVF Decolletage is investing in new plating technology, robotics, and R&D to meet future demands.

Conclusion

From brass rod to finished pin, connector contact manufacturing requires precision, discipline, and expertise. Every step—from alloy selection to machining, plating, and inspection—defines the performance of the final connector.

At AVF Decolletage, we deliver connector pins trusted by aerospace, automotive, telecom, medical, and industrial leaders worldwide.

Request a quote today.

FAQ

Q1: Why is brass the most common material for connector contacts?
Because it balances conductivity, machinability, corrosion resistance, and cost.

Q2: Why is plating necessary?
Plating enhances conductivity, corrosion resistance, and durability.

Q3: What tolerances can AVF Decolletage achieve?
We achieve ±0.005 mm with Swiss CNC machining.

Q4: How do you ensure quality?
With ISO 9001:2015-certified inspection, plating checks, and resistance testing.

Q5: Do you provide certifications?
Yes, we include full material certification samples.

Q6: Can you manufacture custom designs?
Yes, we produce both standard and custom connector pins.