Customizable Pogo Pins with Low Resistance, High Current, and Tailored Fit. Built to Handle Critical Interfaces. Request Custom Specs Today.
Introduction: Customizable pogo pins are quietly transforming the world
In systems where high-speed signal transmission and high current power supply coexist, connectors are often seen as insignificant details. But it is these millimeter level touchpoints that are determining the upper limits of overall performance from drones to medical devices, from AI modules to power tools.
Previous connectors often only served a single purpose: either the current was sufficient but the size was bulky. Either the structure is compact but the durability is poor, or the pressure drop is too large and the loss is significant. But customers’ systems often require customizable connections and are increasingly strengthened. Traditional universal connectors are no longer able to meet high performance and adaptability. Johoty’s customizable pogo pins provide a systematic solution to this core dilemma.
Customizable pogo pins are not standard parts, but matching strategies
The traditional view often regards pogo pins as part of modular inventory. Spare parts.. But in Johoty, pogo pins or pogo pin connectors are defined as dynamic interface management units. It must be specifically adapted according to the following requirements in the customer’s application:
- Contact frequency.
- Current density.
- Mechanical impact level.
- Welding method.
- Process compatibility.
- System board level layout.
The core of customizable is not just about being able to customize, but about customizing based on evidence. Johoty establishes a 3D matching matrix for each customized project, including structure, materials, and electrical parameters. Using this as the underlying modeling, accurately output matching solutions for structure, tolerance, coating, and lifespan.
Contact resistance of 10mΩ, a prerequisite for stability
Low resistance may sound like a simple indicator, but to truly achieve a stable contact resistance of 10mΩ. It is necessary to:
- The deformation is minimal in contact area.
- The elastic closure pressure is stable enough, usually adjusted within the range of 50gf~200gf.
- Uniform coating with thickness is ≥0.5μm.
- Surface roughness ≤Ra0.2μm, ensuring maximum number of micro contact points.
Johoty’s customized process adopts a gold nickel double-layer process, with an outer layer of pure gold not less than 0.5μm. The inner nickel substrate prevents migration and long-term contact does not increase resistance.
After 100,000 compression tests, the contact resistance fluctuation of <15mΩ can still be maintained. Far superior to industry standard connectors, mostly >50mΩ.
Customer application for portable B-ultrasound motherboard power module. Long-term 0.5A charging, using Johoty customized spring needle for 1 year, no significant increase in resistance was observed. The device stability rate has increased from 91.7% to 98.3%.
Significance of high current customizable pogo pins goes far beyond carrying more electricity
For engineers, high current spring loaded pins not only mean they can withstand currents of 3A, 5A, or even 50A. But rather:
- No additional heat generation, the system has friendly thermal management.
- Maintain low voltage drop, typical value <50mV @ 5A.
- No metal fatigue occurs, and the elastic limit of the material is greater than 10 times.
- Compatible with peripheral structures such as copper columns for heat dissipation and graphite thermal conductive sheets.
Johoty’s high current pogo pins often use bidirectional flow structures and embedded balls, T-pins, etc. Plunger and barrel share the same current path, and multiple contacts are designed at the same time. The distribution of heat flux density is very uniform.
Under ±20% load fluctuation, the customizable pogo pin can still control the voltage drop within ±8mV. Satisfy anti-interference requirements under vehicle and military regulations.
Tailored Fit for Customizable Pogo Pins
A often overlooked but crucial issue is the mechanical compatibility of connectors. Micro spacing of 1.00mm, multiple pogo pins array, high vibration environment. If the elasticity coefficient of the pogo pin connector does not match well, the following problems often occur:
- Compression deviation causes pogo pins to shift.
- Excessive elasticity leads to damage to the solder pads.
- After repeated plugging and unplugging, the shell becomes loose.
Johoty’s customizable design process:
- Board end modeling: Collect PCB tolerances, tolerance accumulation paths, mounting processes, etc.
- Simulated crimping: Conduct microstructure fatigue simulation.
- Structural iteration: Through CNC prototype+manual insertion feedback+3D calibration of lifespan compression data.
From data modeling to structural fine-tuning, Johoty can achieve factory-level integration effects. Even completely unfamiliar connectors and PCBs can naturally connect like matching parts.
Why are customizable pogo pins more crucial than you imagine?
In the past, engineering teams often chose universal PINs during the prototype stage, but only discovered after entering mass production:
- Transmission bottleneck is not the chip, but the connection point.
- Increasing PIN number can solve poor contact rate.
- 80% of the overall repair rate is due to connector damage.
And Johoty’s data model shows that: On average, connector related issues account for 31.7% of the overall debugging time in each product development process. Instead of spending three months debugging, it’s better to use customized pogo pins with stronger fit at the starting stage.
The customized is not pogo pins, it’s the customer’s control
Many engineers are concerned that customization means high minimum order quantities and high delivery risks. But in Johoty’s view, the essence of customization is to transfer the decision-making power of product performance from suppliers to customers themselves.
Johoty provides the following support system for Customizable pogo pins:
- MOQ is as low as 3000pcs, and it can flexibly meet client’s actual quantity.
- Sampling cycle is 2 weeks.
- Submit the sample structure CAD and mechanical simulation diagram together.
- Test report: RoHS, salt spray, plug and unplug life, resistance fluctuation.
Customization process is co-creation. Customers don’t need to become connector experts, just explain what goals you want to achieve. Johoty engineers can perform reverse modeling and complete closed-loop adaptation from three dimensions of electricity, heat, and force.
7 applications of customizable pogo pins
Fast charging battery module testing: High speed frequent insertion and removal, requiring a continuous current of 5A and not affecting the size of the partition. Johoty offers customized side bounce structures with a lifespan of over 300,000 cycles.
Smart watch module FPC connection: Space limit controlled within 1.10mm thickness, 0.80mm ultra short stroke pogo pin to meet pressure feedback.
Mini interface inside the optical module: high-speed signal, high temperature environment, low EMI interference requirements. Use a shielding shell and customized hollow needle combination.
Motor controller PWM signal testing interface: Multiple rows of pogo pin matrix are used, and Johoty designs an embedded spring assisted positioning structure.
Medical probe temperature feedback point: adopts medical 316L stainless steel shell, combined with PPS insulation protection. 500,000 plug and unplug verifications in a sterile environment.
UAV flight control motherboard and remote control interface: adopts the right angle scheme, supports 15g seismic acceleration, and has no jumping.
Vehicle door control module data interface: Due to structural limitations and large temperature differences, Johoty customized ripple springs to achieve temperature-compensated contact.
Customizable pogo pin core steps: Concept – Sampling – Verification – Delivery
Johoty provides engineering docking processes for each customized pogo pin project, including:
3D structural pre modeling: Reduce production downtime caused by interference or tolerance issues.
Structural mechanics simulation: Control pogo pin shaped variables within a safe range.
Temperature rise analysis and material selection: Use COMSOL for thermal resistance analysis.
Batch consistency testing: achieve 100% factory resistance testing.
All pogo pins can be traced back to their batches, materials, processes, and testing data.
Conclusion: Customizable connection is intelligent collaboration between systems
For Johoty, each of our pogo pins is not a component, but a physical representation of the interface strategy. In complex systems, customizable pogo pins will carry more than just electricity and signals. It is also the customer’s trust in stability, adaptability, and sustainability. It can fully integrate into the customer’s design essence and reflect maximum stability and performance.
If you are facing challenges such as connector selection, system miniaturization, and high reliability transmission. Or considering how to reduce repair rates and improve interface adaptation efficiency. Please contact Johoty, our customizable pogo pins are engineering partners who can assist you in completing your design.
