Feature: Interconnects
“Custom connectors are only for very high-volume applications, they take a long time to design, tooling is expensive and prototypes take months.” This view may have been true at some point in the past, but, today, custom connectors are more accessible than ever
A new approach to custom interconnect development
By Luke Hulley, Marketing Manager, Bulgin M
any designers think custom interconnect solutions are expensive, require high volumes and take a long time and a lot of money to develop. However, recent technological innovations render these expectations false. In fact, there are many
reasons to consider whether a custom connector solution would make your next design project easier, better or cheaper – or all three. In some cases, a custom connector may have a slightly higher
per-unit cost but offers significantly greater reliability. Tis not only extends the product lifetime and its perceived value, but it
38 February 2022
www.electronicsworld.co.uk
saves the costs of warranty returns and field repairs, lowering the total cost to the manufacturer. In some cases there may be no off-the-shelf solution, which means either compromising on the product specification or using an over-specified standard part that costs more than a customised connector. Many OEMs are now outsourcing specialist designs for
items like power supplies, preferring to focus on their core competencies where they can add value. Te same can apply to custom connectors.
Connection capabilities If there is one single innovation that has improved access to custom connectors, it is 3D printing. In the past, creating prototypes – especially with custom housings – involved upfront financial outlay for tooling and moulds. With this came a high degree of risk and the potential to lose a significant sum of money if the initial mould needed significant revisions or if the idea proved unfeasible. 3D printing has changed this, enabling a direct move from a 3D CAD design to a product in a few hours – without needing tooling. If post-trial changes are required, then the CAD model is simply adjusted and another prototype printed. Whilst this may incur a small cost, it is a far cry from the costs and timescales involved in tweaking or re-making a mould. Plus, 3D printing can work with various materials and incorporate a mix of them into a single design, particularly useful where some aspects of a housing require rigidity and ruggedness whilst others must be flexible. Also, customisation can extend beyond the connector to the whole cable assembly. Oſten, specialist tooling is required and for this reason it is becoming increasingly common to outsource cable assembly to experienced vendors. While many standard cables are available, it is oſten necessary
to specify a specific length or a different pinout for a project. Once a custom assembly is decided upon, additional features such as colour coding or specific keying (to avoid mis-plugging)
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