IN-HOUSE MANUFACTURING
50+ CNC turning and milling centers produce connector shells, inserts, and coupling nuts from aluminum alloy, stainless steel, and brass. Tolerances held to ±0.005 mm. Every batch is laser-measured against CAD specs before release.
Multi-axis machines run unattended overnight with automatic tool changers and in-process probing — zero human error, consistent output.
High-speed precision stamping presses produce contacts from beryllium copper, phosphor bronze, and brass at speeds up to 1,200 strokes per minute. Automated optical inspection checks every contact for burrs, dimensional drift, and surface defects.
In-house electroplating lines apply gold, silver, nickel, and specialty coatings — all controlled to MIL-DTL-45204 and ASTM B488 standards. No outsourced plating. We control the chemistry.
Full toolroom with EDM, wire cutting, and CNC grinding. We design and build every mold in-house — no waiting on third-party tooling suppliers. Mold life: 500,000+ shots.
Incoming resin is tested for melt flow index, moisture content, and contamination before it enters production. We batch-trace every lot back to the supplier certificate.
Robotic pick-and-place systems load contacts into molds before overmolding. Eliminates manual insertion errors and ensures consistent contact positioning across millions of parts.
Need a custom insert? Our mold shop can produce prototype tooling in 5–10 days. First article samples ship within 2 weeks of drawing approval.
| Process | Equipment | Standard |
|---|---|---|
| Contact insertion | Automated insertion machines with force monitoring | MIL-DTL-38999 §4.5.4 |
| Coupling torque | Digital torque testers (±0.01 N·m) | MIL-DTL-38999 §4.5.8 |
| Contact retention | Push-pull force gauges | MIL-DTL-38999 §4.5.12 |
| Insulation resistance | 500 VDC megohmmeter, 100% test | >5,000 MΩ @ 25°C |
| Dielectric withstanding | AC/DC hipot tester, 100% test | 1,500 VAC (sea level) |
| Shell conductivity | 4-wire Kelvin measurement | <2.5 mΩ shell-to-shell |
| Visual / dimensional | Automated optical inspection + CMM | IPC-A-610 Class 3 |
| Leak test (hermetic) | Helium mass spectrometer | <1×10⁻⁸ cc/sec He |
-65°C to +200°C thermal shock chambers. 500-cycle endurance per MIL-STD-810 Method 503.
500-hour salt fog exposure per ASTM B117. 1,000-hour available for naval/marine specs.
Automated mating cycle testers. 500+ mating cycles with contact resistance measured every 50 cycles.
Random vibration to 40g, mechanical shock to 100g per MIL-STD-202 Methods 204/213.
We welcome factory audits. Walk the production floor, review our QC records, meet the engineers who design your connectors.
Or start with free engineering samples — test compatibility before you commit.
Email: info@airoadcon.com · Phone: +86-189-9192-7716