How Can pressfit Pins Achieve Highly Reliable Connections in a Very Small Space

As new energy vehicle adoption rises, automotive electronic architecture is shifting from distributed designs to domain-centralized, central computing. Component density on BMS and ECU PCBs is increasing rapidly.

In limited circuit board space, welding or screw fastening takes up space and creates reliability issues under tough conditions. Achieving dense, reliable electrical connections in minimal space is a key challenge for automotive electronics engineers.

Pressfit Pins: The Art of Connection in Small Spaces

Pressfit pins (Press-Fit Pins) are designed with a unique cross-section and, once pressed into a PCB through-hole, offer key benefits such as maximizing connection reliability in limited spaces and simplifying assembly, effectively tackling the challenge of high-density automotive electronics connections.

The Ultimate Pursuit of Space Efficiency

The press-fit connector, using a solder-free process, is directly pressed into the plated through-holes of the PCB. This method provides electrical and mechanical connections while saving valuable board space. It allows components to be packed more densely, maximizes the usable area for more functional chips, and improves overall system integration.

The Key to High Reliability

The reliability of pressfit terminals comes from their elastic structure, which generates continuous radial force for multi-point contact, ensuring low and stable contact resistance and preventing damage from welding heat. Their design delivers robust, high-reliability connections, maintaining performance across extreme temperatures, shock, and vibration.

Facing the harsh demands of the automotive environment, high-quality pressfit terminals must also possess the following characteristics:

• Vibration resistance: Meets ISO 16750-3 standards for road vehicle electronics by keeping connections stable during random vibration and shocks.
• Salt spray corrosion resistance: Withstands 96+ hours of salt spray, preventing failure in corrosive environments.
• Low insertion force and high holding force: Balances insertion and holding force for efficient assembly and reliability over time.

Process Compatibility and Cost Advantages

Press-fit connectors are optimized for automated high-speed press assembly, which improves efficiency. Their solderless process avoids issues like incomplete soldering, bridging, or flux residue. These attributes lead to higher productivity, reduced defect rates, and lower overall manufacturing costs.

Application Value in BMS/ECU Scenarios

In BMS, pressfit terminals support battery module voltage sampling, temperature acquisition, and high-voltage interlock signal circuits. Their dense, solderless, and vibration-resistant design enables reliable, long-term multi-cell monitoring. In powertrain and chassis ECUs, pressfit terminals transmit sensor signals, control signals, and auxiliary power for robust and safe autonomous driving and intelligent chassis operation.

Hejustamping- Your Faithfully Supplier of Pressfit Terminals

Dongguan Heju Precision Electronics specializes in pressfit pins and automotive wiring harness terminals, offering research, design, and production capabilities. With extensive experience and certifications, including ISO9001, ISO14001, and IATF16949, we provide comprehensive quality inspection and electroplating support. We cooperate closely with customers to deliver customized solutions. Contact us for your pressfit pins project.