Connectors are essential to industrial manufacturing, ensuring that controls and sensors work as intended. Choosing the right connector can be the difference between your company’s smoke detector saving the life of a family or a line of faulty products needing to be recalled.

Custom connectors and off-the-shelf connectors each have unique advantages. Depending on your manufacturing needs, timeline, and budget, one type of connector may be more suitable than the other. 

Here are some factors to consider when choosing the right connector for your product:

Standard Connectors

Standard connectors can be used in a variety of products. Because they are mass-produced by multiple suppliers, there is a steady supply of standard components at competitive prices.  

In addition, standard connectors are typically used to set the ‘standards’ for an industry or application. These connectors will undergo extensive testing to evaluate their reliability in harsh environments and ensure their performance in a specific application.

However, there are some drawbacks to using off-the-shelf connectors. Despite their mass production, you can not control the supply chain and there may be shortages of common connectors, or the supplier may choose to discontinue a part. 

Additionally, there could be concerns with not owning the design of the part.  If a supplier makes even a small change to its standard connector, it could alter a product’s ability to function. In highly regulated industries, this could bring production to a standstill as even the smallest of changes needs to be studied and approved before a product can be put in market. 

Despite these drawbacks, standard connectors have many benefits. If you can find one to work in your application, you should go with it. But standard connectors will have limitations. For instance, you can only work with certain types of pins, which may or not be suitable for your application. When this is the case, a custom connector is the way to go.

Custom Connectors

For applications with a specific purpose and function, custom connectors can be a preferred option. 

Custom connectors come in handy when the technology, environment or design of your product is not compatible with a standard connector.  For example, consider an outdoor application where a standard pin may fit your design but is prone to corrosion. In this instance, a custom plated pin from Bead Electronics would prevent corrosion, and ensure durability and reliability in harsh conditions.

While the initial design and development of custom connectors sometimes require a higher upfront investment and additional planning time, the long-term cost savings and enhanced performance often outweigh the initial costs. Bead Electronics excels in providing cost-effective, custom solutions that keep your project on schedule and within budget. 

With more control over the design, manufacturers have an easier time creating connectors that not only fulfill specific roles but also meet stringent regulatory requirements. Using custom connectors means you are not limited to certain pin types. Instead, you have the flexibility to select the ideal length, shape, and material to perfectly suit your application's needs, resulting in an optimal solution. 

When to Consider a Custom Connector 

Custom connectors are a quick and cost-effective solution, especially when:

• Mechanical and electrical/electronic requirements are not met with standard connectors
• Needing extra protection from extreme environmental conditions
• Failing to meet creepage and clearance standards
• Failing to meet testing standards
• Needing to align PC board contacts with your product's unique layout
• Facing long lead times or the lack of specialized parts

Read more about design considerations for custom connectors here.

Finding the Right Connector for Your Product

Whether you’re working with custom connectors or standard ones on your project, Bead Electronics is here to help you find the best materials and connector solutions. We are a global designer and manufacturer of electronic connector pins and have been operating in our automated site in Connecticut for over 100 years. 

When a standard connector just won’t cut it, Bead Electronics makes designing and manufacturing custom connectors easy and affordable. 

Contact us to speak to a specialist today!