From Terminals to Shells: The Craftsmanship Behind High-Quality Connector Manufacturing
In the world of electronic devices, connectors are the foundation of stable transmission.
A truly high-quality connector is not defined by appearance, but by the precision of its connector manufacturing process.
Stability is not an added feature — it is the core language of every connector.
From terminal materials to plating thickness and shell design, each detail determines the product’s durability and reliability.
1. Terminal Material: Balancing Conductivity and Elasticity
The terminal is the heart of signal transmission.
High-quality connectors typically use high-conductivity copper or phosphor bronze,
striking an ideal balance between electrical conductivity and mechanical elasticity.
This design maintains low contact resistance, ensuring consistent contact pressure through repeated mating cycles, while minimizing deformation and performance degradation over time.
2. Gold Plating Thickness: Microns That Define Longevity
Gold plating thickness plays a decisive role in connector longevity.
Depending on the application, the most common options are 1μ, 3μ, and 15μ:
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1μ – for standard signal or consumer electronics.
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3μ – improves wear and oxidation resistance, extending lifespan by about three times.
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15μ – designed for extreme environments such as medical, industrial, or outdoor systems.
To ensure consistent quality, plating undergoes microscopic inspection and adhesion testing
to verify uniform thickness and bonding strength, meeting IPC-610 and UL1977 standards.
This ensures stable conductivity and low resistance even after long-term use.
3. Shell Material: Shielding Strength and Corrosion Resistance
The connector shell provides not only mechanical strength but also signal shielding and corrosion protection.
Common materials include copper shells and iron shells:
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Copper shells offer excellent conductivity and salt-spray resistance, ideal for industrial, communication, and medical devices.
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Iron shells provide high strength and cost efficiency, often used in general indoor environments.
Engineers select the right material combination based on environmental and cost factors
to achieve the best balance of conductivity, corrosion resistance, and mechanical durability.
4. Reliability Testing: Stability Proven Through Testing
High-quality connectors undergo multiple tests to ensure performance and reliability in real-world conditions.
Typical test items include:
contact resistance, mating cycles, salt-spray, dielectric withstanding voltage,
and insulation resistance.
These evaluations confirm that connectors can maintain stable signals and safe electrical performance
under high-frequency, humid, or long-term usage conditions.
✨ Every connector’s precision and detail reflect the expertise and experience behind its manufacturing.
From material selection to surface treatment and reliability testing, each process step plays a critical role in ensuring long-term stability and performance.
🏢 About Walta Electronic
Walta Electronic specializes in high-quality connectivity solutions, providing a full range of USB Type-C, HDMI, DisplayPort connectors, Board-to-Board connectors, power connectors, as well as custom cables and wire harness assemblies. With precision manufacturing and advanced R&D, we serve premium applications across consumer electronics, medical technology, industrial control, Telecommunications, and automotive electronics — helping our partners stay competitive with performance they can trust.
Our mission is to enhance connectivity solutions, ensuring superior compatibility and long-term competitiveness for our customers.
👉 Follow us on LinkedIn for the latest product updates and connector insights.
從端子到外殼：高品質連接器（High-Quality Connector）的製造工藝
在電子產品的世界裡，「連接器」是所有傳輸穩定性的起點。
但高品質連接器（High-Quality Connector）不是靠華麗外觀，而是由 製造細節（Connector Manufacturing） 一層層堆疊而成。
穩定性並非附加價值，而是連接器最核心的語言。從端子材質、鍍層厚度到外殼結構，每一個細節都決定了產品的壽命與可靠度。
一、端子材質（Terminal Material）：導電性與彈性的完美平衡
端子是整個訊號傳遞的核心。常見的高品質連接器會使用 高導銅 (High-Conductivity Copper) 或 高彈性磷青銅 (Phosphor Bronze)，在導電性能與機械彈性之間取得最佳平衡。
這樣的設計能維持低導通阻抗（Low Contact Resistance），確保多次插拔後仍保持穩定接觸力，降低疲勞變形與性能衰退風險。
二、鍍層厚度（Gold Plating Thickness）：微米之間的壽命差距
鍍金厚度是決定連接器壽命的關鍵之一。
依應用需求常見有 1μ、3μ、15μ 三種鍍層厚度：
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1μ：用於一般訊號或消費型應用。
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3μ：可提升耐磨耗與抗氧化性能，壽命延長約三倍。
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15μ：適合極端環境下的醫療、工業與戶外應用。
為了確保品質，鍍層通常需經過顯微檢測與附著力測試，確保厚度均勻、附著牢固，並符合 IPC-610、UL1977 等國際標準。這能讓端子在長時間使用後仍維持穩定導通與低阻抗表現。
三、外殼材質（Shell Material）：防鏽與導電的雙重防線
外殼除了提供結構強度，也影響屏蔽效果與抗腐蝕能力。
常見的外殼材料為 銅殼 (Copper Shell) 與 鐵殼 (Iron Shell)：
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銅殼 具備優異的導電性與抗鹽霧特性，適合工控、通訊與醫療設備。
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鐵殼 則以高機械強度與成本優勢，在一般室內應用中常被採用。
根據應用環境與預算條件，工程師會選擇最適合的材料組合，以兼顧導電性、防鏽性與成本效率。
四、品質驗證（Reliability Testing）：穩定，從測試開始
高品質連接器需通過多項測試，以確保在實際應用中的可靠性。
常見測試項目包括：
導通阻抗 (Contact Resistance)、插拔壽命 (Mating Cycles)、鹽霧 (Salt Spray)、耐壓 (Dielectric Withstanding)、以及 絕緣阻抗 (Insulation Resistance)。
這些測試確保連接器能在高頻、高濕度或長期使用的環境下，
維持穩定訊號與安全的電氣性能。
✨ 每一顆連接器的精密細節，都體現了製造工程中的專業判斷與長期經驗累積。
從材料選擇到表面處理，再到最終的品質驗證，都是高品質連接器得以長久穩定運作的關鍵。
🏢 關於 Walta Electronic
Walta Electronic 專注於高品質連接解決方案，產品涵蓋 USB Type-C、HDMI、DisplayPort、Board-to-Board Connectors、Power Connectors，以及 客製化線材與端子線組。我們憑藉精密製造與專業研發技術，服務應用於 Consumer Electronics、醫療科技、工業控制、Telecommunications與車用電子 等高階領域，致力於協助合作夥伴以穩定性能立足競爭市場。
我們的使命是持續優化連接技術，確保客戶的產品在 兼容性、穩定性與長期競爭力上保持領先。
👉 歡迎追蹤我們的 LinkedIn，掌握最新產品資訊與連接器趨勢觀點。