When a U.S. based injection molder needed a right-angle pin for insert molding that didn’t exist in any standard catalog, they faced a unique manufacturing hurdle.
Their client, a global leader in motion and control technologies, required a molded pump cap featuring a contact pin longer than anything currently available on the market.
Through precision tooling and engineering, Bead Electronics developed a custom solution.
A Custom Right-Angle Pin That Didn’t Exist
The customer needed a right-angle pin to be insert molded with an exceptionally long leg, longer than any previously manufactured pin in their experience. Off-the-shelf solutions were not an option.
This wasn’t just a sourcing issue. The pin’s length exceeded the limits of standard equipment and tooling, requiring entirely new pin manufacturing techniques.
Why Bead Electronics?
At Bead Electronics, we specialize in designing and manufacturing custom contact pins that meet exacting standards for electrical and mechanical performance. With in-house tooling capabilities and a deep understanding of molding processes, Bead was uniquely equipped to take on this challenge.
Tooling a Complex Pin Design
Coming up with a custom solution was a multi-step process:
1. Assessing Equipment for Long Right-Angle Pins
The first challenge was ensuring the die bed could support the custom pin’s length. Our engineers took precise measurements down to thousandths of an inch to validate the setup.
2. Developing a New Bending Process for Long Pins
Bead engineered a new bending method to produce the 90-degree bend in the long-leg right angle pin without hitting the machine bed — a major breakthrough in process design.
3. Controlling Spring Back in Brass Pins
Achieving a perfect bend required compensating for spring back, a common challenge when forming brass pins for insert molding. The team over-bent the pin by a few degrees and fine-tuned the process through testing.
Our expertise in precision tooling allowed us to build accuracy into the tool itself. This minimized variation and ensured every pin was consistent, repeatable, and mold-ready.
5,000 Custom Right-Angle Pins Delivered
Bead Electronics successfully produced 5,000 custom pins for insert molding that met the plastic molder’s specs. The parts were approved by both the client and the end customer and are expected to go into production in 2026.
Even before testing results are finalized, the project is a technical success, expanding Bead’s capabilities and showcasing our ability to solve complex design problems in insert molding pin manufacturing.
Ready to Design Your Own Custom Contact Pin?
If your molded component requires a non-standard solution, Bead Electronics offers the engineering precision, custom tooling, and manufacturing agility to deliver results.
Contact us to get started with a custom quote - or start designing today with our solid wire pin configurator!
