COMMENT
When tolerances trust in miniature electronics manufacturing
Designing the world’s smallest two-pole reed relay, measuring just 5 mm × 5 mm, pushes the practical limits of miniaturisation. It’s one of Pickering Electronics’ most compact reed relay designs to date and a reminder of a reality in electronics manufacturing, where smaller designs leave far less room for error.
P
rogress in electronics is often measured in fractions of a millimetre. While individual components may be tiny, the consequences of failure rarely are. That’s why modern electronics manufacturing relies on automation and repeatability, with densely packed systems leaving assembly lines highly sensitive to dimensional variation. In high-volume production environments, components must also more than meet perform consistently through automated handling and assembly, where even minor dimensional differences can disrupt throughput.
At the same time, R&D teams are under pressure to reduce footprints, shorten development cycles and bring new designs to market quickly, while preserving long-term reliability.
For many, this prods regular reassessment of manufacturing routes and suppliers as part of prudent supply-chain resilience, ensuring repeatability and scalability as designs shrink.
Pickering’s challenge Known for over 50 years of reed relay expertise, Pickering Electronics design and manufacture reed relays for test & measurement, semiconductor automated test equipment (ATE) and other demanding applications.
That’s how the company has built a reputation on miniaturisation and dependable performance in applications where failure is simply not an option. This challenge is one shared by much of the electronics sector but felt more acutely at the high-reliability end of the market. For instance, reed relays can incorporate precisely formed metal subcomponents into high-value assemblies. However, this
raises the stakes because small variations early in the supply chain can compromise performance later in the build process, when rework is expensive or impractical. Components must also meet extremely tight tolerances too. Not just for performance reasons, but because they feed directly into automated assembly processes where even small deviations can cause disruption across production lines and, by extension, across the wider group.
Overlay this with the need for rapid prototyping, frequent design iteration and product lifecycles that can span decades, the challenge multiplies. So, how do you maintain precision and repeatability across the supply chain while pushing the boundaries of miniaturisation?
Establishing the manufacturing route
Pickering’s relationship with Precision Micro 12 MARCH 2026 | ELECTRONICS FOR ENGINEERS
began as a response to these constraints. Chemical etching offers a reliable way geometries while supporting rapid design iteration as relay footprints continued to shrink.
Precision Micro was selected based on its ability to deliver tight tolerances, predictable quality and dependable turnaround. And, as Pickering’s portfolio evolved, chemical etching became embedded into supporting early prototypes and volume manufacture.
Like many manufacturers operating in high-reliability markets, Pickering periodically reviews alternative processes, such as stamping, as part of robust supply chain management. Yet alternatives can struggle to meet the combined demands of accuracy, repeatability and cost when applied to extremely small, complex
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