FR-4 Connectors, Ideal for Prototypes and Low-Volume Production

With respect to prototype and low volume connector requirements, it is often difficult to avoid costly Non-Recurring Engineering (NRE) charges up-front. However, Mill-Max Mfg. Corp. can provide custom, low-quantity connectors while avoiding tooling costs thanks to our in-house FR-4 epoxy milling capabilities. As well as injection-molded connectors for high-runs, Mill-Max utilizes glass filled epoxy material to provide custom-designed connectors tailored to meet your needs at low volume, with no minimum order quantity.

Mill-Max has the unique ability to create these connectors as many of our standard machined components incorporate a press-fit feature, making them suitable for assembly into FR-4 material. This makes batch production simple and quick, as we often have the machined components on the shelf. See Introduction to Mill-Max Custom Capabilities for the full range of what we customize.

You may also see this capability referred to as a machined laminate insulator. The two terms describe the same thing: an insulator milled from sheet stock rather than injection molded, with FR-4 the laminate used most often. See Custom Connector Manufacturing for how it compares to molding and 3D printing.

Benefits of Custom Connections

Designing a custom FR-4 connector is an extremely fast way to translate design concept into a tangible product. We understand that speedy turnaround times are crucial in today’s competitive market, and a quick prototype build can put you ahead of the game.

A custom FR-4 connector also adds convenience to your PCB assembly process. It can overcome production difficulties by incorporating all required contacts into a ‘one-piece’ substrate for simple board placement. The substrate also holds the parts in place during the soldering process. This is especially important for surface mount components using pin-in-paste techniques. The risk of parts ‘floating’ on the board is greatly reduced when using a connector.

Custom Connectors Design

Our ability to mill and machine FR-4 allows the customer to create an interconnect to match the footprint of virtually any component, no matter how obscure the configuration or pin spacing. With near limitless milling capabilities in the x and y axes and extremely tight positional tolerances, we can custom design a connector to many shapes and sizes, even accommodating very fine pitch connector requirements. The Path to Miniaturization covers the space-saving levers in more detail.

Mill-Max can also ‘mix-and-match’ different machined components into the same FR-4 connector. Whether you need to socket a wide range of lead sizes or incorporate alignment pins for thru-hole stability, Mill-Max can unite these different components into one assembly. As well as machined components, Mill-Max can also add other components to the connector such as threaded inserts for fastening purposes.

FR-4 also allows Mill-Max to create unique ‘carrier’ products that enable multiple pins or receptacles to be deposited onto a board in one action, soldered and then removed.

Materials for Prototype Connectors

With material thickness available from .010” - .500” we are sure to have an option that fits your requirement. For applications where exposure to high temperature environments is expected (beyond the capabilities of FR-4), we offer G-30 Polyimide/Glass Laminate material, suitable for higher temperatures. Where the receptacle contacts also need to run hot, beryllium nickel contact clips are available in place of the standard beryllium copper.

Suitable for all RoHS soldering profiles, low volume FR-4 connectors from Mill-Max may be a perfect solution for your next prototype or low-volume production requirement. Send us your footprint, pin spacing, and material thickness on the custom part worksheet to start the process.

Next sectionCustom Capabilities FAQs: minimum order quantities, custom lead times, tooling charges, tolerances, and high-temperature and non-magnetic material options.