In the modern world, where everything is getting more and more electrified in various domains, connectivity which is electrical, must function with optimum precision. The production of electronics components that connect and power various industries including automotive, aerospace, and other satellites make use of sturdy, precision electrical connectors.
Brass Die Casting for Electrical Connectors
Brass die casting stands out as a process which combines efficiency with unrivalled properties of materials.
Brass as an alloy used for die casting makes connectors for electric vehicles, EVs, power grids, amd consumer electronics as it has unparalleled 25%-30% dispersal of electricity compared to other substitutes like aluminum and zinc alloys.
Thermal Control
Unlike other metals, brass efficiently dispels heat from the surface which inhibits overheating in applications that require high current such as charging ports and industrial switchgears.
Withstands moisture, chemicals, and environmental stress which makes it highly robust. This is key for the automobile industry and for connectors which find application in outdoor equipment.
Strength & Durability
Die-cast brass components resist deformation under mechanical stress, ensuring stable connections over thousands of mating cycles.
Key Applications of Die-Cast Brass Connectors
EV Charging Systems: Battery terminals, charging inlet housings
Industrial Controls: PLC components, relay bases, terminal blocks
Consumer Electronics: USB-C ports, power adapters, socket housings
Aerospace & Defense: Avionics connectors, radar components
Renewable Energy: Solar inverter connections, wind turbine wiring
The Die Casting Advantage Over Alternatives
Unlike machining or stamping, brass die casting delivers:
– Complex Geometries: Single-piece designs with integrated threads, flanges, and cavities.
– Mass Production Scalability: High-volume output with minimal post-processing.
– Cost Efficiency: Near-net-shape production reduces material waste by up to 60%.
– Dimensional Stability: Tight tolerances (±0.1mm) for seamless assembly.
Case Study: Automotive High-Voltage Connectors
A leading EV manufacturer switched to brass die casting for battery busbars after aluminum components failed thermal cycling tests. The brass solution:
Reduced operating temperature by 18°C
Increased service life by 200%
Lowered assembly costs via snap-fit integration
Innovacasts’ Expertise in Electrical Brass Die Casting
At Innovacasts, we specialize in precision brass die casting for mission-critical connectors. Our capabilities include:
Alloys: C85700, C86500, C87850 (optimized for conductivity)
Secondary ops: CNC, plating, EMI/RFI shielding
Quality: ISO 9001, PPAP, and CTQ-based process control
Future Trends: Brass in 5G & IoT
As 5G infrastructure and IoT devices demand smaller, hotter-running connectors.