Through-Hole Pogo Pin Connector Should Fit The Design
Johoty always ensures our connectors work within a defined mechanical shell, PCB stack-up, mating position, assembly process and electrical load. Johoty needs to design it for the limited available space and non-perfectly aligned mating surfaces. We need to solve the required different compression from one application to another. We also need to solve the constrained PCB hole, mounting height, contact geometry and termination method from clients’ existing design.
That is why Johoty always approaches a through hole pogo pin connector as an engineering interface. We can review the relationship between PCB hole, installed height, mating surface, working stroke, force, contact geometry and electrical requirements. And then we recommend a perfect configuration for our clients.
When Standard Pogo Pins Are Not Enough:
A standard part can be an efficient choice when its dimensions and performance match the application. However, Johoty’s custom through hole pogo pin connector becomes more appropriate when your design requires a different combination. Including overall length, barrel diameter, plunger geometry, and working height. And you want to combine compression stroke, spring force, contact surface, solder-tail geometry. Also, you want to integrate mounting-hole dimensions, plating specification, electrical current, environmental requirements, and mechanical tolerance.
Designed Around the Expected Interface:
Johoty clients’ engineering objective is not simply to make the pogo pin smaller, stronger or longer. They often ask Johoty to create a contact system in which the mechanical and electrical requirements support each other. For example, clients prioritize package height and controlled contact force in their compact wearable devices. However, other clients always focus on mechanical durability, vibration tolerance and stable electrical performance for their industrial interface. So, Johoty always makes different engineering decisions for the same basic through hole pogo pin connector.
Specifications of Through Hole Pogo Pin Connector
| Parameter | Value |
|---|---|
| Product Type | Through Hole Pogo Pin Connector |
| Free Height, Working Height | 1.60–20.00 mm, 1.50–19.90 mm, custom. |
| Working Stroke, Self-Cleaning Wiping Stroke, Floating Contact Stroke | 0.10–5.00 mm, custom. |
| Working Contact Force | 0.05–100.00 N, custom. |
| Plunger Diameter, Barrel Diameter | 0.13–5.50 mm, 0.50–12.50 mm, custom. |
| PCB Through-Hole Diameter | 0.50–3.50 mm, custom. |
| Mounting Tail Length, PCB Thickness | 2.0–10.00 mm, custom. |
| Pogo Pin Pitch | ≥2.0 mm typical, ≥1.27 mm for selected compact configurations |
| Pin Count per Array | 2–500+ contacts. Johoty can customize up to 4,000 pins. |
| Array Rows | 1–4 rows, Round, custom. |
| Continuous Current, Peak Current | 1–2 A typical, up to continuous 50A per pin for thermal validation. Peak current is up to 80A~100A per pin. |
| Contact Resistance, Insulation Resistance | ≤50 mΩ typical, custom as low as 10mΩ. ≥1,000 MΩ. |
| Rated Voltage | Up to 550VDC. |
| Contact Material | Copper alloy, brass, BeCu, TeCu, SUS304, etc. |
| Spring Material | Stainless steel, BeCu, SWP-B, SUS631, etc. |
| Contact Plating Thickness | 0.1–1.0 μm Au typical, up to 5.0μm. Based on 3.0~5.0μm Nickel plating. Optional composite plating. |
| Operating Temperature, Storage Temperature | −55°C to +125°C, −40°C to +105°C, 10–90 RH, non-condensing |
| Mating Cycles | Up to 500,000 cycles, standard life cycles of 10,000 times. |
| Alignment Compensation | ±0.10–±0.50 mm, custom. |
| Angular Compensation | ±2°–±5°, standard of ±3° |
| Power Contact Allocation | 1–50A typical, custom. |
| Signal Contact Pitch | ≥1.27 mm, custom. |
| Power + Signal Pin Count | 2–500+, custom. |
| Anti-Misconnection | 1–4 keyed / asymmetric locating features, custom. |
| Soldering Temperature | Up to 260°C for ≤10s in wave soldering. |
| Prototype Quantity | 10–100 pcs, |
| Production Quantity | 1,000,000+ pcs/day. |
How Through Hole Pogo Pin Connector Works?
Conventional rigid connectors depend heavily on the dimensional relationship between two mating surfaces. Johoty introduces controlled mechanical compliance of the spring loaded pins into the connection of our through hole pogo pin connectors. As the mating surface compresses the plunger, the internal spring maintains contact force while accommodating various mechanical variations.
Johoty designs a through hole pogo pin for repeated mating, compact packaging, replaceable modules, docking interfaces or controlled mechanical movement. We don’t simply integrate a spring in the pogo pin. We need to control the relationship perfectly between contact force, stroke, geometry, materials, plating, installation and alignment.
Mechanical Compliance for Real Assemblies:
Many clients told Johoty that their products are not assembled in a perfectly ideal coordinate system. They often saw PCB or enclosure tolerances, mating components, assembly variation and repeated mechanical movement. These slight gaps can all influence the contact interface.
Johoty can properly engineer our spring loaded connector and help manage these variables within the defined working range.
Electrical Contact Depends on Fine Tuning Dimensions:
Johoty won’t separate electrical performance from mechanical performance during our designs. We always design contact shape and size carefully, surface finishing, contact force and compression, materials and applications.
Clients can get contact resistance as low as 10mΩ, continuous current of up to 50A per pin. including long-term stability of up to 500,000 times too. So, Johoty always evaluates the complete interface first instead of a component alone.
Designed for Power, Signal or Mixed Interfaces:
Many clients ask Johoty through hole pogo pin connector for different electrical functions. We can perfectly layout one connector arrangement to carry power and carry low-level signals, while combining a multi-contact interface.
Johoty always finalizes the perfect configuration according to current, voltage, low or high-speed signal, contact spacing, temperature rise and mechanical dimensions. Our clients always get helpful and useful connection solutions after verifying our through hole pogo pin connectors.
Performance Is Defined by Client’s Project Instead of a Single Number
Johoty always ties every performance figure to a defined configuration and test condition during our design. So, our engineers always need to know what to achieve under a defined test condition and what conditions to apply. Therefore, Johoty always recommends specifying through hole pogo pin connectors using a complete engineering parameter set.
Controlled Contact Force:
Johoty can accurately define the spring force to enhance electrical stability and mechanical load. We know a weak force can significantly reduce contact reliability. However, an excessive force can increase mating load or place unnecessary stress. We can design a perfect through hole pogo pin connector based on the force curve and working stroke.
Stable Electrical Contact:
We can engineer the contact interface around the required electrical performance for continuous current, surface finishing, and contact resistance. You can rest assured of gold-plated contact surfaces for controlled contact performance and corrosion resistance. And, you can confirm final electrical ratings against the selected design, mating, and test method.
Repeated Mating:
Many clients ask spring-loaded contacts for interfaces with repeated connection and disconnection. Johoty can develop pogo pins and springs according to the mechanical life target and working conditions. Many clients often value lifecycle performance, we can recommend initial contact resistance, working stroke, and spring force. Then, we need to also define mating speed and frequency, environmental conditions, and end-of-life contact resistance criteria. Clients can get a meaningful lifecycle, for example, 10,000 times, 100,000 times or 500,000 times.
Environmental Requirements:
Our clients often need to solve temperature variation, humidity, vibration, dust, corrosion or other environmental stresses. Johoty can define the correct material, plating and mechanical configuration according to the actual environment. You can contact us for continuous 125℃, IP67/IP68, 10G acceleration, hybrid connections for power and data signal. When environmental reliability is the primary concern, Johoty don’t propose a pogo pin solely from a standard connector catalog.
Configure Through Hole Pogo Pin Connector Around Your Mechanical and Electrical Constraints
We always design a through hole pogo pin connector very simply from the outside. But we make the engineering variables high interconnection behind its interface. Johoty supports configurable solutions across the areas to determine whether a through hole pogo pin connector fits clients’ products.
Mechanical Configuration:
Johoty can solve clients’ constraints after perfectly configuring pogo pin length, barrel/plunger diameter, working/compressed height, and working stroke. And, we can accurately design tail diameter/length based on mounting-hole diameter, plunger-tip/barrel geometry, pin arrangement, Pitch, and positioning features.
Spring Configuration:
Johoty can engineer the spring according to the required initial force, working force, maximum compression, and working stroke. We can accurately design high end spring based on SUS631, BeCu, SWP-B, and stainless steel, and so on. You can completely achieve the expected mechanical life, available internal space, and operating temperature.
Contact Surface and Plating:
For perfect electrical behavior, wear, corrosion resistance and application compatibility, Johoty always values material and surface finishing. We consider the design, plating for the contact surfaces and other conductive components in our through hole pogo pin connectors. Our clients can get perfect material and plating combination to meet expected current, mating cycles, environment and target reliability.
Termination and PCB Integration:
Johoty can provide through-hole mounting by direct PCB integration, and the connector tail passes through the board. Clients can directly solder the through hole pogo pin connector on to PCB according to the wave soldering process. And, clients can also coordinate the termination geometry with the PCB hole and assembly requirements.
Single Pin or Multi-Contact Arrangement:
Johoty can support individual spring-loaded pin as well as engineered multi-contact arrangements in a through hole pogo pin connector. You can get high current, data and signal of high and low frequency/speed based on EMI shielding, IP67/68, etc. And, you can also get a complete connection interface rather than isolated pins.
Designed for Integration Into the Assembly Process
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PCB Compatibility:
Johoty can perfectly match the mounting tail and barrel dimensions with the PCB hole and board construction. Where necessary, we can review the connector geometry against the actual design based on clients’ PCB drawing or hole specification.
Soldering Considerations:
We always look into the selected component geometry and manufacturing environment in depth. Then, we can integrate through-hole solder mounting into different PCB assembly processes as complete electrical and mechanical connection. Our clients can effectively solder through hole pogo pin on wave soldering station or manual soldering workstation as well.
Mating Interface:
Johoty always clearly defined the mating surface. For best engineering results, we can provide mating material, mating surface geometry, and mating height. We can also offer expected compression, alignment tolerance, mating frequency, and environmental conditions. Johoty can design the through hole pogo connector around the actual interface instead of an assumed one.
Design Verification Before Production:
Johoty can recommend critical dimensions and performance before volume production for a custom through hole pogo pin connector. Our clients can rest assured of the mating cycles, smooth alignment, and effective integration in clients’ assembly processes. And, they can get the finalized drawings, samples, dimensional inspection data, test results and applicable compliance documentation.
From Prototype to Production of Johoty Through Hole Pogo Pin Connector
Johoty’s objective is to keep the through hole pogo pin connector consistent as the project moves from initial concept to production. Because we can avoid the unnecessarily expensive of connector development as a manufacturer of protype and finished goods.
You can start with a drawing, sample, physical reference part or functional requirement. Johoty can then work through the critical variables and identify a manufacturable configuration.
Requirement Review: Johoty needs to review the application, mechanical structure, PCB interface, electrical requirements and operating environment.
Engineering Configuration: Critical dimensions and performance parameters are defined clearly before Johoty starts the drawings. Where the design is not yet finalized, we can identify adjustable parameters and get clients’ confirmation and approval.
Prototype and Sample: Our clients can verify prototype or sample quantities on mechanical fit, mating behavior, electrical performance and assembly compatibility.
Validation: Clients can check critical requirements against defined acceptance criteria.
Production: Once clients approve Johoty’s design, we will transfer production requirements into a controlled manufacturing specification.
Built for Applications Where Space, Movement and Contact Reliability
Johoty can combine the electrical continuity of the spring-loaded interface with controlled mechanical compliance for electronic systems.
Wearable and Compact Electronics:
Many clients often require severe restrictions on PCB area, enclosure height and serviceability in their compact electronics. Johoty can design a compact spring-loaded interface in our through hole pogo pin connector. It can avoid unnecessary mechanical constraints which a conventional rigid connector faces.
Medical and Healthcare Equipment:
Clients often ask Johoty to design stable electrical interfaces for their medical electronics. They also require controlled connection performance and consistent quality. We can finalize the connector based on perfect materials, finishing, durability and lifespan, environmental limits and validation.
Industrial Electronics:
In industrial equipment, clients have to solve challenges caused by vibration, temperature variation, repeated service access and demanding assembly conditions. Johoty can design such through hole pogo pin connector based on high spring force with SUS631, BeCu hard gold plating. It can be integrated as part of client’s complete mechanical system.
Test Fixtures and Functional Test Equipment:
These test devices always require high repeated connection frequency to test points or modules. So, many clients often ask Johot to customize spring-loaded contacts with at least 100k life cycles and high reliability. We can strictly design the connector to match client’s tester based on contact force, working stroke, tip geometry, cycle life.
Charging and Docking Interfaces:
Johoty can simplify detachable power or signal interfaces of our connectors for docking systems and modular electronic assemblies. Because Johoty can design the suitable magnetic force and spring force, clients are easy to connect and disconnect. And, we always evaluate charging, current rating, temperature rise, contact resistance, mating cycles and mechanical alignment together.
Automotive and Transportation Electronics:
Many clients always face the challenges of vibration, temperature variation and long-term reliability in transportation environments. Johoty can design the perfect through hole pogo pin connector with high spring force and high durability. Clients can validate the final connector performance and reliability under the actual mechanical and environmental conditions.
Custom OEM / ODM Electronics:
Many clients use a proprietary PCB, housing or mating structure for their new project. Sometimes, they also need to update the existing connection methods or look for new functions. Then, Johoty is the right customization supplier and manufacturer. We can offer you custom through hole pogo pin connector around the actual interface.
Customization Engineering and Validation of Johoty Through Hole Pogo Pin Connector
Many customers initially request a shorter pogo pin, higher spring force or rate current, or smaller diameter. So, Johoty needs to solve enclosure interference, insufficient compression, PCB tolerance, excessive mating load, contact instability or assembly difficulty. And, Johoty’s engineering process is to identify the real constraint before defining the final geometry.
What you need to provide:
You don’t need to have a finished connector. If you provide Johoty with any of the following, it is helpful for us. Please send us existing connector sample, PCB drawing, your 2D drawing, or 3D CAD model. We can also customize the perfect through hole pogo pin connector based on your housing drawing and mating-part drawing. Sure, you need to know electrical specifications, target spring force, and required working stroke. At the same, we want to know your required lifecycle, photos with dimensions, or application description.
What Johoty can review:
Johoty engineering focus on reviewing your mechanical structure, PCB mounting, contact geometry of plunger tip and contact pad. We double check the compression range or working stroke, including initial stroke and full stroke, as well as spring force. To ensure you get perfect through hole pogo pin connectors, we also look into your electrical requirements, material and plating. If there are complex working conditions, it’s needed for us to check your assembly process, environmental conditions, and production feasibility.
Engineering Before Quotation:
Many clients want to order through hole pogo pin connector for technically sensitive applications. Johoty always needs to know clients’ detailed requirements, restrictions or constraints. Then, we won’t treat the quotation as the first engineering decision. We also provide clients with our MOQ, lead time, samples based on FOB, and so on. Overall, you can see Johoty’s process from requirement, engineering review, configuration, to prototype, your validation, then mass production. And, you can get a much strong and reliable supply chain of Johoty through hole pogo pin connector.
Manufacturing Capability:
Johoty can provide our clients with through hole pogo pin connector solutions based on our ±0.01mm CNC machining. We can achieve it by our 5-axis and 6-axis CNC machining, CMM inspection and engineering support. Including the team work of our R&D engineering team, CNC engineering, process engineering, quality engineering, and production lines. Johoty can support clients with samples in 2-week lead time, and MOQ of 3,000pcs or flexible custom quantity on demand. Rest assured of our connectors on tight tolerance of ±0.01mm, low contact resistance of 10mΩ. And spring force of 5gf based on SUS631, SWP-B or BeCu, high current of continuous 50A, and so on.
FAQ About Through Hole Pogo Pin Connector
What is a through hole pogo pin connector?
Johoty designs the through hole pogo pin connector to mount as is spring-loaded electrical contact through PCB holes. We can ensure the spring-loaded plunger tips maintain controlled contact against mating surface. Its tail pins can provide electrical and mechanical connection to PCB with various hole diameter and thickness. Then, you can get compact packaging, controlled contact force, repeated mating or mechanical compliance.
How to identify a through hole pogo pin connector and an SMT pogo pin connector?
The primary difference is the PCB mounting method. Johoty designs through hole pogo pin connector by a tail or mounting structure that passes through a PCB hole. While we design an SMT pogo pin connector for surface mounting on soldering pad on PCB. You can choice them depends on PCB construction, assembly process, mechanical requirements and available installation space.
Can Johoty customize a through hole pogo pin connector?
Yes. Johoty can customize it based on dimensions, working height/stroke, spring force, and contact geometry. We also think about plating, mounting structure, tail configuration and multi-pin arrangements. Our clients can get perfect connector solutions for the project and confirm everything good through Johoty’s engineering documentation.
Can I send a drawing instead of a complete connector specification?
Yes. It’s helpful for Johoty to get PCB drawing, 2D drawing, 3D models, existing component sample, or dimensioned photograph. We can design the expected through hole pogo pin connector based on them. Sure, you are possibly not to define some requirements yet. Johoty can review your special application and help identify and finalize the parameters.
What spring force should I choose for my through hole pogo pin connector?
Johoty always accurately design the right spring force for every application. For the required spring force, we need to refer to the mating surface, available stroke, and number of contacts. And we also need to check mechanical load, alignment condition, lifecycle requirement and electrical objective. Johoty can define the correct working stroke and mating conditions before selecting the spring force.
Can a through hole pogo pin connector carry both power and signal?
Yes, it can. Johoty can configure a pogo pin interface for power, signal or a combination of contacts serving different electrical functions. However, we also have to design different electrical and mechanical requirements for power and signal contacts. Because we need to consider current, contact resistance, thermal conditions, signal characteristics and spacing together during the design stage.
How many lifecycles can Johoty through hole pogo pin connector achieve?
Johoty designs the through hole pogo pin connector depending on specific construction, materials, and spring with wire diameter and materials. With SUS631 spring, we can achieve 100,000 life cycles and <5% spring force attenuation. Sure, the connector lifespan is also determined by gold plating, working stroke, mating surface and test conditions. Johoty can work toward a project-specific lifecycle and design standard 10,000 times, 100,000 times, and 500,000 times for you.
Can Johoty through hole pogo pin connector fit vibrating environment?
Yes, it can, when Johoty properly engineers the contact force, stroke, mating geometry, retention and materials. In general, the spring-loaded contacts have high spring force and can involve mechanical movement or vibration. Many times, Johoty through hole pogo pin connector needs to deal with high vibration, 10G~50G acceleration. Our client can validate the final design under the actual vibration profile and mechanical applications.
What information does Johoty need to quote a custom through hole pogo pin connector?
Johoty need to get the most useful PCB hole size, overall height, required working height, and stroke. And, we also need to know the desired spring force, current, contact resistance target, and mating surface. It is essential for the required mating cycles, operating temperature, plating requirement and annual quantity. If these values are not available, you need to provide Johoty with a drawing or sample for our engineering review. In the formal quote, you can see lead time of 2 weeks, MOQ 3000pcs, unit price, delivery costs, etc.
Can Johoty provide samples before mass production?
Yes, Johoty can offer samples instead of free samples, because many projects need custom through hole pogo pin connector. For an initial customization, the largest investment is plastic molding cost for non-waterproof or injection cost for IP67 or IP68. With molding cost, Johoty can arrange 5~10pcs free prototype samples for you. And, we can evaluate custom samples before production. You will get perfect mechanical performance, mating cycles, electrical performance and assembly compatibility.
Can Johoty provide CAD drawings and documentation?
Yes, Johoty can provide technical documentation according to the product and project stage. Depending on the configuration, this may include 2D drawings, 3D CAD data, datasheets, inspection information and applicable compliance documentation. We always review client’s detailed requirements and work out 2D drawing and 3D model for approval. And then we start the sample production and send to clients for validation. We always ensure available documentation based on the actual configuration of through hole pogo pin connector.
How to start a custom through hole pogo pin connector project with Johoty?
For Johoty, we need to review the drawing, PCB specification, existing connector sample or application requirements as soon as possible. We need to confirm the connector functions, including rated current, mechanical space, working stroke, mating frequency and environmental conditions. Johoty can propose suitable through hole pogo pin connector solutions and then offer quotation or samples to our clients.
Have a Challenge Related to Through Hole Pogo Pin Connector?
Many clients think the right through hole pogo pin connector is the closest dimensions on Johoty’s catalog page. Let Johoty tell you: It’s the one that works with your PCB, mating structure, electrical requirements, assembly process and lifecycle consistently and predictably.
If you already have a defined through hole pogo pin connector specification, send it to Johoty for quotation now. If the specification isn’t finalized, send Johoty the engineering problem. Johoty can discuss with you based on a drawing, PCB file, 3D model, existing sample or dimensioned photograph. We can review the requirements and help determine the defined mechanical and electrical parameters before moving into sampling and production.
