Phosphor Bronze Bulb Socket Terminal for the Automotive Industry

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An automotive industry customer approached us to manufacture the vanity mirror bulb socket terminal shown here. Once the die was designed and built, a first article inspection report was submitted to the customer for approval. Due to the high annual volume of parts, this die was built with carbide inserts for both cutting and forming stations. This helps maintain die life. The part is composed of .016” thick CA521 phosphor bronze, and required tolerances of ±.003”. Manufacturing was performed on our high speed 4 post 30 ton Bruderer press. In order to meet the customer’s automatic assembly requirements, the parts were run on a reel-to-reel format. This feature also allows for automatic packaging which provides added protection for the finished parts, and very accurate part counts. We currently produce 8 million of these components annually for this client, delivering finished products on a Just-in-Time (JIT) delivery schedule. Shipments include all applicable Material Certification and Certificates of Conformance. 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.  To learn more about this custom progressive die stamping project, please see table below or contact us directly.