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50 Ohm Connector (Kovar Pin)

Material: Kovar alloy (per ASTM F-15)

Manufacturing Method:

• Formed on a slide machine

Notable Features:

• Micro size Kovar pin
• For the small connectors needed in RF devices
• Spherical radius on one end, wire bondable flat on the other end

Advantages:

• Formed from wire with no scrap developed
• The flat is very uniform and presents an exceptional wire bond surface.
• The corner (or "edge") break at the end of the flat has a radius of .001" max.
  

• Good for wire bonding near the edge of this feature.
  
• Very good finish on the spherical radiused end with no machining lines
• Micro size allows this component to be used on very small connectors & hermetic seals

Wire Wrap Pins

Material: CDA 2102 copper

Manufacturing Method:

• Multi-Die cold-formed/coined/notched on a slide machine

Notable Features:

• Coined flat area with a notch to provide a precise location and a holding feature for the wire wrap.
• Headed flange used as a stop and locating feature for circuit board insertion.

Advantages:

• Material waste is minimal. The part is formed from oxygen-free high conductivity copper wire round wire.

• An inexpensive way to produce high-volume pins with a coined/notched and headed feature on the part component.
• Production speeds are high allowing for low production costs. Much faster than machining.

Cap Lead Combination Pin Terminal

Material: Kovar alloy per ASTM f-15 (nickel/cobalt alloy - glass to metal seal quality)

Manufacturing Method:

• Multi-Die cold formed

Notable Features:

• Very large volume head combined with small diameter shaft
• Very high surface finish. No machining lines or machining tit present at either end of the part.
• A very good surface finish present on the sealing surfaces. No leak paths.
• Note the recessed trapezoidal shape in the top head surface.

Advantages:

• Material waste is minimal.
• Production speeds are high allowing for low production costs. Much faster than machining.

• Normally, this component would be a two-piece welded unit combining a Kovar disc (ie: a button) with a terminal lead. This component is cold-formed as a one-piece unit therefore there is no weld/braze joint between two different pieces and no assembly error.
  
• Concentricity of all diameters is near perfect: TIR approx. .002".
  
• Surface finishes are smooth for good hermetic sealing characteristics. No machining marks/spirals/inclusions are present.

High Volume Kovar Pins

Material: Expansion alloy: Kovar (cobalt/nickel alloy) per ASTM F-15.

Manufacturing Method:

• Multi-Die cold formed

Notable Features:

• A very good surface finish present on the sealing surfaces. No leak paths.
• Very large head volume on top of a small lead diameter.

Advantages:

• Material waste is minimal.
• Cold forming the pin eliminates the presence of spiral machining lines.

• Production speeds are high allowing for low production costs. Much faster than machining.
  
• Very smooth die mounting surface on top of head diameter.
  

Auto Rectifier: Headed C Band

Material: CDA 102 copper (oxygen-free; high conductivity copper)

Manufacturing Method:

• Cold-headed pin with coined C-Bend on a slide machine.
• Complete off the machine.

Notable Features:

• The coined area is formed into a precise C-Bend.
• Large-headed area (heat sink and braze attach platform).
• Smooth top head surface (RMS 32 and better) with zero voids or inclusions or folds on the braze surface.

Advantages:

• Material waste is minimal. The part is formed from copper round wire.

• The C-Bend area is a stress relief feature providing longitudinal give protecting the die attachment.
• Production speeds are high for this high-volume piece allowing for low production costs.

Shoulder Pin Connector

Manufacturing Method:

• Produced from coiled wire .101" diameter.
• Manufactured completely from cold forming. No secondaries on slide machine.
• Tooling designed & built in-house.

Notable Features:

• High thermal conductivity while resisting thermal softening at high temperature (or high radiation).
• Maintains strength at high temperatures.
• Part combines a cold-headed flange with a flattened area for wire bonding.
• Surface finishes better than 32 RMS
• Burrless

Advantages:

• No machining lines or cut-off deformations present.
• The headed portion is used as a stop for insertion into a circuit board and the flattened area is to provide a pad for an electrical connection (ie: wire bond). Incorporated into a one-piece design.