The Collaborative Process of Developing Custom High-Power Interconnect Solutions

The decision to develop a custom power interconnect is typically driven by a convergence of constraints:unprecedented power density,integrated cooling,a unique form factor,or the need to combine power,signal,and data in one sealed module.When no catalog part exists,a structured co-development process is the path forward.

The journey begins with a deeply collaborative definition phase.Engineers from both the client and manufacturing partner work to translate system-level requirements into component-level specifications for the contact,insulator,and housing.Early 3D modeling and finite element analysis(FEA)for thermal and mechanical stress are used to explore concepts virtually.

With a direction set,the prototyping phase commences.Critical contact components are machined via precision CNC.This phase is iterative:samples are tested for contact resistance,temperature rise under load,and mechanical lifecycle.The ability to rapidly turn around prototypes and provide test data is a core value of an engaged partner.

The final stage is production qualification and ramp-up.A full validation test plan is executed on production-intent samples.Once qualified,the focus shifts to manufacturing process control,ensuring every unit meets the exacting standards set during development.

The path from custom power connector design to a reliable high current interconnect solution hinges on a partner capable of prototyping and testing custom power terminals iteratively.ZMAX operates as this integrated partner,combining precision CNC machining for rapid prototypes with in-house electrical and thermal testing.This vertical control over the process—from material to validated component—ensures that a custom design is not just a prototype,but a manufacturable,reliable product that solves your specific packaging or performance challenge.