Phosphor Bronze Spring Contacts for Highway Lighting, Reel-Packed

A fixture maker for highway lighting was getting its spring contacts loose in bags. Bulks arrived mixed orientation, operators wasted time singling them out, and a few contacts came back from the field with bent tips from transit damage.

We stamped and formed the contact from pre-plated #510 phosphor bronze strip, then packed it reel-to-reel so the customer's assembler could feed parts straight from the spool. The silver pre-plate was applied on coil before stamping, which keeps plating on the contact face only and avoids a barrel-plating step.

Outcome

• 2,600,000 contacts per year on a weekly pull
• Tolerances held to ±0.005 mm through form and cut-off
• Reel packing eliminated the sort-at-incoming step; bent-tip complaints dropped to zero reported
• Delivery location: customer plants in Europe (export experience on record)

Specifications

ASTM-grade phosphor bronze (C5191 family) · silver pre-plate on coil · reel-to-reel or loose packing options · progressive die · MOQ 10,000 pieces