SM Contact Corporation

SM Contact Corporation SM Contact is a worldwide specialist in automated solutions for splice crimping and pin insertion Use this social network to contact us in dialog!

SM Contact offers splice crimping and pin electrical connection expertise all over the world making a point of problem engineering qualification. Our analysis provides customized connectors that solve customer’s problem rather than connectors that the customer asked for. We intend to make the highest quality products that can guarantee end-user safety even in such high-risk industries as automotiv

e and healthcare. We attempt to empower our employees with an emphasis of identifying their strengths and inspiring them to fulfil their potential. Corporation has offices in France (headquarters), Germany, Russia (engineering) and China. Agents are in Australia, Austria, Brazil, Czech Republic, Denmark, Great Britain, Italy, Japan, Poland, South Africa, Spain, Sweden, Switzerland, USA.

Soldering will NOT disappear from EV power electronics by 2035.But it will stop being the default.As EV architectures mo...
11/06/2026

Soldering will NOT disappear from EV power electronics by 2035.

But it will stop being the default.

As EV architectures move toward higher voltages, higher temperatures, and more compact designs, engineers are increasingly choosing connection technologies based on load profile — not habit.

We already see the shift happening:

→ SiC power modules are moving from solder to silver sintering for die attach because higher operating temperatures demand stronger thermal performance.

→ Compact automotive sensors and sealed housings increasingly use press-fit connections:
✔️ no heat
✔️ no flux
✔️ no cleaning process
✔️ insertion force monitored in real time

→ High-current busbars and battery tabs are rapidly adopting laser welding for precision and contamination-free assembly.

But solder is not going away.

For low-voltage PCB assemblies, control modules, infotainment, and many ADAS systems, traditional reflow soldering remains:
✔️ cost-effective
✔️ scalable
✔️ reliable enough for the application

The real industry shift is not “the end of solder.”

It’s the end of solder as the automatic default.

By 2035, EV electronics will likely rely on multiple joining technologies working side by side:
• sintering for high-temperature power semiconductors
• press-fit for reliable PCB interconnects
• laser welding for high-current connections
• soldering for standard PCB assembly

Different technologies for different physical demands.

And that’s exactly where power electronics engineering is heading.

A conventional combustion vehicle contains around 200–300 connectors.An electric vehicle?Up to 800.More connectors. More...
08/06/2026

A conventional combustion vehicle contains around 200–300 connectors.

An electric vehicle?
Up to 800.

More connectors. More power electronics. More thermal stress. More vibration. And zero tolerance for failure.

That’s one of the reasons why press-fit technology is rapidly growing in automotive electronics.

Unlike soldered joints, press-fit connections use elastic deformation to create permanent mechanical pressure inside the PCB hole.

No solder cracking.
No thermal fatigue.
No flux contamination.

Just stable metal-to-metal contact designed to survive:
✔️ vibration
✔️ temperature cycling
✔️ high-current applications
✔️ long vehicle lifetimes

This matters especially in:
→ EV inverters
→ Battery management systems (BMS)
→ ADAS modules
→ Onboard chargers

For Tier-1 suppliers, press-fit is not only a reliability solution — it’s a production solution.

Insertion force can be monitored in real time during assembly, allowing immediate quality control directly at the machine.

No waiting until final inspection to discover a failed connection.

As EV architectures become more compact and power-dense, connection technology has to evolve with them.

And the market reflects that:
Automotive is now the largest segment of the global press-fit connector industry.

The shift is already happening.

Already next week, we will be exhibiting at PCIM Europe in Nuremberg!Come visit us at Hall 5 – Booth 141 and discover O-...
05/06/2026

Already next week, we will be exhibiting at PCIM Europe in Nuremberg!

Come visit us at Hall 5 – Booth 141 and discover O-pin, our innovative interconnection solution for power module applications.

We look forward to meeting industry partners, engineers and innovators during the exhibition.

See you at PCIM Europe!

Layout doesn’t care about your assembly process.If the connector design requires pins at 0° on one side and 90° on anoth...
01/06/2026

Layout doesn’t care about your assembly process.

If the connector design requires pins at 0° on one side and 90° on another, the insertion process has to follow — precisely.

Most standard insertion systems don’t.

The usual workaround?
Two separate assembly cycles:
→ insert 0° pins
→ re-fixture the component
→ rotate tooling
→ insert 90° pins

More handling. More operator time. More alignment risk.

For high-volume sensor production, those extra seconds quickly become real cost.

That’s why advanced insertion systems now combine both orientations in a single automated cycle.

With a rotary-table process:
✔️ 0° and 90° pins inserted automatically
✔️ no re-fixturing between operations
✔️ continuous production flow
✔️ up to 3,600 pins/hour
✔️ reduced cycle time and handling errors

This is especially critical in modern automotive sensors and EV electronics, where compact closed housings leave almost no room for traditional assembly methods.

In many applications, the pin must pass through both the plastic housing and PCB in one operation.

That requires more than machine precision.
It requires connector geometries designed for both PCB retention and plastic anchoring.

As electronics become smaller and more integrated, assembly technology has to evolve with the layout — not against it.

A tiny bend in a copper pin.No solder. No bolts. No glue.Yet this connection can survive 30+ years of vibration, thermal...
29/05/2026

A tiny bend in a copper pin.
No solder. No bolts. No glue.

Yet this connection can survive 30+ years of vibration, thermal cycling, and mechanical stress in IGBT modules and EV power electronics.

How?

Press-fit technology uses an “eye-of-the-needle” zone inside the pin.
This elastic section is slightly larger than the PCB hole.

When inserted, the pin compresses like a spring.
Once seated, it pushes outward against the plated hole walls, creating permanent gas-tight mechanical pressure.

That pressure IS the electrical contact.

No solder joints to crack.
No thermal stress from soldering.
No overheating of ceramic substrates.

For qualified press-fit pins:
→ Contact resistance: ΔRc < 0.5 mΩ
→ Stable after thermal cycling from −40 °C to +85 °C
→ Controlled insertion force for process monitoring

Press-fit technology delivers:
✔️ repeatable assembly
✔️ stable long-term contact
✔️ cold insertion process
✔️ reduced thermal stress
✔️ high production reliability

One small elastic deformation.
Decades of reliable performance.

Are you using copper sleeve connector insertion technology in IGBT modules?Then you probably know how sensitive the proc...
27/05/2026

Are you using copper sleeve connector insertion technology in IGBT modules?

Then you probably know how sensitive the process can be.

The challenge?
Column diameters must stay within ±0.01 mm tolerance.

As soon as the column diameter differs by just 10 microns and goes out of tolerance:
• pins start bending
• insertion becomes unstable
• assembly failures increase
• expensive scrap is created

And when a product contains many pins, the cost of failure grows dramatically.

But this can be avoided.

With our new O-Pin technology, connectors are supplied already assembled with the copper sleeve/column.

That means:
✔️ no insertion process at customer production
✔️ no pin damage during assembly
✔️ no tolerance-related insertion failures
✔️ lower scrap costs
✔️ higher process reliability

Discover more about O-Pin technology:
o-pin-smcontact.eu

What does connector reliability really mean?A connector may work perfectly in the lab.The real question is: what happens...
21/05/2026

What does connector reliability really mean?

A connector may work perfectly in the lab.
The real question is: what happens after years of vibration, heat, humidity, and thermal cycling?

Modern connectors used in automotive, power electronics, industrial automation, and EV systems are exposed to extremely demanding operating conditions.

That is why reliability testing has become a critical part of connector engineering.

Typical harsh environment testing includes:

⚡ Thermal cycling
Repeated heating and cooling to simulate long-term operation and material expansion stress.

🔧 Vibration testing
Continuous mechanical vibration to evaluate contact stability and resistance to micro-movement.

💧 Humidity and corrosion exposure
Testing connector performance under moisture and aggressive environmental conditions.

🔥 High-current load testing
Validation of temperature rise, contact resistance stability, and long-term electrical reliability.

🔄 Mating cycle testing
Repeated insertion and extraction to evaluate wear resistance and mechanical durability.

Very often, failures do not start with catastrophic damage.
They begin with small changes:
• unstable contact resistance
• mechanical fatigue
• microscopic deformation
• gradual thermal degradation

As power density increases and electronics become more compact, connector reliability becomes just as important as semiconductor performance itself.

Because in real industrial environments, reliability is not theoretical.

It is engineered.
And it is tested under stress.

Digital Transformation in Selection: From Catalog to AI AssistantThe way engineers select connectors and design PCB layo...
18/05/2026

Digital Transformation in Selection: From Catalog to AI Assistant

The way engineers select connectors and design PCB layouts is changing rapidly.

According to recent industry discussions highlighted by Wevolver, engineers are increasingly using AI-assisted tools during component selection and electronic design workflows.

This changes the expectations placed on component suppliers.

Today, it is no longer enough to simply provide a PDF catalog.

Modern engineering workflows increasingly require:
• complete 3D CAD models
• high-resolution technical drawings
• machine-readable datasheets
• accurate dimensional data
• digital assets compatible with ECAD/MCAD systems
• fast access to technical documentation during early-stage design

In many cases, AI-assisted systems and automated design environments can only work efficiently if component data is structured, detailed, and digitally accessible.

At SM Contact, we see this as an essential part of modern engineering support.

That is why we provide:
✓ full 3D models
✓ detailed technical drawings
✓ comprehensive datasheets
✓ engineering support at every project stage

Our goal is to make SM Contact solutions fully Digital Ready for modern electronics development workflows.

As engineering moves from static catalogs toward intelligent digital selection environments, component manufacturers must evolve as well.

The future of connector selection is not only physical compatibility — but digital accessibility.

Magnet wire stripping remains one of the most underestimated bottlenecks in coil, transformer, and electric motor manufa...
15/05/2026

Magnet wire stripping remains one of the most underestimated bottlenecks in coil, transformer, and electric motor manufacturing.

Traditional processes often require:
• mechanical scraping
• thermal stripping
• chemical treatment
• laser stripping
• solder pot operations

All of them add complexity, cycle time, tooling wear, and process variability. In high-volume production, even small inconsistencies during enamel removal may lead to unstable electrical contact, damaged conductors, or reduced long-term reliability.

At SM Contact, we approached this challenge differently.

Our P-IN auto-piercing technology enables direct connection of enameled magnet wire without pre-stripping operations.

The principle is simple:
specialized serrated contact geometry penetrates the enamel insulation during the crimping/insertion process itself, creating a stable gas-tight electrical connection in one step.

This allows manufacturers to:
✓ eliminate separate stripping operations
✓ reduce production cycle time
✓ avoid thermal damage risks
✓ improve process repeatability
✓ simplify automation integration
✓ reduce production cost

Applications include:
• transformers
• electric motors
• inductors
• EV charging systems
• industrial electronics
• electromagnetic coils

Sometimes the biggest manufacturing improvement is not adding another process step — but removing one entirely.

More about P-IN technology:
https://p-in-smcontact.eu/

SiC vs IGBT: where does each technology really win?The industry conversation often sounds like:“SiC is the future. IGBT ...
11/05/2026

SiC vs IGBT: where does each technology really win?
The industry conversation often sounds like:
“SiC is the future. IGBT is obsolete.”

Reality is more nuanced.
⚡ SiC advantages:
• higher switching frequency
• lower switching losses
• better efficiency
• reduced cooling requirements
• smaller and lighter system designs
This makes SiC ideal for:
→ fast EV charging
→ compact converters
→ aerospace
→ high-efficiency applications

But IGBT technology still remains highly competitive.
🔋 Where IGBT still wins:
• industrial drives
• railway systems
• renewable energy
• UPS systems
• cost-sensitive high-current applications

Why?
Because in many real-world conditions:
✓ switching frequency is moderate
✓ robustness matters more than maximum efficiency
✓ thermal requirements are manageable
✓ system cost remains critical

What is often overlooked is that reliability issues in power modules frequently originate not from the semiconductor itself — but from the interconnect architecture and assembly process around it.

As power density increases, manufacturers face:
• tighter tolerances
• thermal cycling stress
• connection stability challenges
• more demanding automated assembly

Whether using SiC or IGBT, reliable interconnect solutions remain essential for long-term system stability.

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