"We're using a connector that we believe is too expensive and we need a cost down. Can you design a connector for us that meets our performance needs but significantly reduces the price?"
Product: SMT board to board socket
Application: Consumer audio
Quantity: 2,000,000pcs p/a
Issues: The customer was forced into using an over engineered part as the only available specification exceeded the application needs of up to 25 mating cycles.
As a result the connector was too expensive.
Solution: Redesign of contact & housing to reduce material usage
Reduction of gold plating area and thickness by introducing nipples on contact points
Use of Mylar P+P film in place of plastic P+P cap (reducing cost and allowing better heat transfer avoiding warping in IR reflow process)
Design brief to delivery: 10 weeks
Tooling cost: $35,000 ($0.0175 per part if amortized over 2,000,000pcs)
Result: The product design met the customers brief first time, on time, and with a reduction in price of 47% (including amortized tooling costs)