Phosphor Bronze Leaf Contact with Gold Inlay

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A manufacturer of medical equipment asked us to develop this leaf contact that was to be used in a thumbwheel switch for a medical application. We prototyped this part using Chemical Etching and several low cost forms. We provided the customer with actual part samples, which allowed them to proof their concept at minimal cost. Once the part was approved, we designed and built a die in-house that produces 500,000 of these leaf contacts annually.

This bi-metal project was composed of .007” thick CA521 phosphor bronze with gold inlay. The contacts were manufactured on our 30 ton Bruderer press. Due to the design and precision of our tooling, we were able to meet tolerances of ±.001”. This product also required special packaging, which utilized tool actuators that automatically cut the parts after four segments and placed them into custom trays. Quality control was maintained through a vision system as well as an optical comparator. Along with a batch sample retention system we maintained a zero defect to the customer. Shipments include all applicable Material Certification and Certificates of Conformance. For more information on this precision progressive die stamping project,  please see table below or contact us directly.