Cable connectors are manufactured using different techniques depending on the material they are made of, which is typically either metal or plastic.
Manufacturing Process
Here's a detailed breakdown of how cable connectors are typically made:
Plastic Connectors
- Injection Molding: This is the primary method for creating plastic cable connectors.
- Plastic pellets are fed into an injection molding machine.
- The machine heats these pellets to a high temperature, melting them into a liquid state.
- The molten plastic is then injected into a mold cavity that has the desired shape of the connector.
- The plastic cools and solidifies within the mold, taking its form.
- Finally, the mold opens, and the finished plastic connector is ejected.
Reference: "Depending on the connector's material, the connector will either be formed from metal or plastic. If the connector is made of plastic, typically, the connector is created via an injection mold where plastic pellets are melted at a high temperature and morphed into a particular shape before cooling and solidifying."
Metal Connectors
- Machining: For metal connectors, several machining processes may be used:
- Turning: This involves rotating a metal rod or block against a cutting tool to form the connector's basic shape.
- Milling: Material is removed from a block using a rotating cutting tool to shape the connector's precise features and contours.
- Stamping: Sheet metal is pressed into a die to create the connector shape. This is especially common for pins, contacts, and other small metal components within the connector.
- Casting: Molten metal is poured into a mold, allowing it to solidify into the required connector shape.
- Other Manufacturing Methods: Depending on the complexity and precision needed, other techniques like powder metallurgy or electrical discharge machining (EDM) can also be used.
Different Connector Components
Cable connectors usually have different parts, each created using the techniques mentioned earlier:
- Housing: The outer casing of the connector, often made from molded plastic.
- Pins and Contacts: These are usually metal and are produced by stamping, machining, or casting methods. They provide the electrical connection between the cable and the device.
- Insulation: Made of plastic, this component insulates the contacts to prevent short circuits.
Assembly
Once the individual components are manufactured, they are assembled to create the final, usable connector. This assembly process is often automated using robotics.
