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Making the Switch

A new customer gets more than they ask for.

Our customer was in the process of designing a new switch for a power distribution application that would be capable of shutting off power remotely. They contacted PEP Brainin because of our expertise in manufacturing electrical contacts. As we learned more about the application, we discovered the customer required additional metal components.

Customers consulting PEP Brainin for our electrical contact expertise soon appreciate the value of our contact assemblies, metal stampings, and solutions integrating other capabilities within the PEP portfolio such as plastic molding. Above: PEP Brainin electrical contact assemblies.

Customers consulting PEP Brainin for our electrical contact expertise soon appreciate the value of our contact assemblies, metal stampings, and solutions integrating other capabilities within the PEP portfolio such as plastic molding. Above: PEP Brainin electrical contact assemblies.

In addition to the components, our customer asked for technical support for their switch development. Once contact size, material, and switch mechanics were determined, we were asked to assist with sample components and prototype assembly manufacturing.

Based on the results of our customer’s tests, several adjustments were recommended during the development process that allowed our customer to achieve the performance goals. Higher volume prototypes were required for field trials. Once the design was proven, we moved forward with production tooling, including automated assembly automation. One of the components required plastic overmolding, which was supported by PEP’s microPEP team.

What had  started out as an inquiry for electrical contacts blossomed into a value-added PEP Brainin project that included contacts, stamping, overmolding and assembly for millions of components annually.

And that’s not all. PEP Brainin has since supported a design modification that has substantially reduced the amount of precious metal required for cost reduction.

This story is far from unique. Our customer was initially attracted to PEP Brainin by one of our areas of expertise – in this case electrical contacts – only to discover that we can provide one-stop implementation of several other related capabilities including stamping, overmolding, assembly and production automation. Because our customer didn’t have to worry so much about the switch components, they could focus more attention on what they do best. In the process they got a switch solution that was better – and lower cost – of the off-the-shelf product they had considered using.