Two Solid Pins Folded Into One Stamped Terminal — Welding Deleted

A part for an automotive electrical assembly came in as a drawing with two solid pins to be bought separately and resistance-welded onto a stamped terminal base. Purchased pins, a weld station, weld inspection, and cycle time — all for two bits of metal.

Our DFM proposal rebuilt the pin as a formed feature: the stamping wraps a fully sealed barrel around the pin geometry so base and pin exit the die as one piece. Nothing is welded, nothing is sourced second-hand.

Outcome

• Part count dropped from 3 to 1; the weld station came off the customer's line
• Fit, form, and function preserved against the original drawing
• 500,000–1,000,000 pieces annually on a 30 T press, Alloy-family copper strip 0.8 mm
• Angle held to 0.5°; tin over copper flash finish 0.5–2.0 µm
• Redesigned part prices at a fraction of the welded assembly

Specifications

copper alloy strip (C5191/C194 family) · 0.8 mm · 2.0 mm progression · sealed-barrel pin forming · fast DFM turnaround