Design notes from our engineering team: the equations, failure modes and decision tables behind spring-loaded contacts, battery holders and connector systems.
These are written for the engineer who has to specify the part, not the buyer who has to place the order. Each note states what it is computing and on what assumptions, cites the standards it relies on, and says plainly when a value has to be determined by test rather than quoted from a catalogue.
How to Calculate Pogo Pin Spring Force (With Worked Examples)
Why the two force figures on a spring pin datasheet are both the wrong design point, the vibration margin that decides intermittent opens, and the seven items an RFQ needs.
SMT Battery Holder Reflow Profile: Where the Process Window Actually Closes
SAC305 needs 217 C at the joint while the housing must stay under its HDT, and J-STD-075 says the supplier defines the thermocouple location. Plus the four ways out when the window closes.
Terminal Extraction Force: Why the Housing Breaks Before the Terminal Comes Out
Shoulder planing, bent lances and the TPA trap that scraps more housings than any other single cause. What EIA-364-35 actually measures, and the extraction limit worth writing into your work instruction.
High-Current Pogo Pin Design: 5 Critical Engineering Factors
In the era of fast charging and industrial automation, high-current pogo pin connectors are replacing traditional leaf springs in many mission-critical applications. But designing an interface that reliably handles 5 A to 30 A+…