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Brass Spring Contact Pins (Pogo Pins)
Brass Spring Contact Pins (Pogo Pins) – Spring-Loaded Connector Pins for PCB Testing and Charging
Brass spring contact pins, commonly known as pogo pins, are precision-assembled spring-loaded electrical contacts consisting of a brass barrel, a spring-loaded plunger, and a compression spring. They are used in PCB test fixtures, battery contact assemblies, charging connectors, docking stations, wearable electronics, medical devices, and blind-mate connectors. Electrical Accessories India manufactures and exports brass pogo pins with gold-plated plungers and barrels, offering reliable electrical contact over millions of compression cycles. Price: US$ 11.50/kg
Product Overview
Construction of Brass Pogo Pins
A brass spring contact pin (pogo pin) assembly consists of three components: (1) the outer barrel made from free-cutting brass CW614N or beryllium copper, providing the housing and mounting interface; (2) the plunger (probe tip) made from hardened beryllium copper C17200 or brass, which makes the actual electrical contact with the mating surface; and (3) the compression spring typically made from stainless steel 302/304 or music wire, providing the contact force between 30 gF and 300 gF depending on application. The spring force maintains contact pressure across mechanical tolerances, vibration, and thermal expansion variations in the assembly.
Plunger Tip Geometries
Pogo pin plunger tips are available in multiple geometries: round (ball) tip for PCB pads and flat contacts; crown tip (3-crown or 5-crown) for through-hole vias and oxidized surfaces; chisel/flat tip for bus bars and flat contacts; cup tip for spherical solder balls (BGA); spear/needle tip for penetrating conformal coatings; and serrated tip for wire/cable contacts. Tip selection depends on the mating surface type, surface finish (ENIG, OSP, silver, tin), and contact reliability requirement per IPC-9252 test standards.
Electrical Performance of Pogo Pins
Gold-plated brass pogo pins achieve initial contact resistance below 20 mΩ per IEC 60512-2-1. For high-cycle ICT and functional test applications, hard gold (0.5–2 µm) over nickel-plated plunger surfaces maintains contact resistance below 50 mΩ after 1,000,000 compression cycles. Current-carrying capacity ranges from 0.5A (0.5 mm diameter miniature pogo pins) to 15A (large-diameter power pogo pins). Signal frequency bandwidth extends to 10 GHz for coaxial pogo pin configurations.
Mounting and Installation
Brass pogo pins are available in press-fit (interference fit into fixture plates), solder-tail (wave and reflow solderable), through-hole (snap-in into fixture holes), and surface-mount (SMD pogo pin with solder pad) mounting configurations. PCB-mount pogo pins are supplied on tape-and-reel (T&R) packaging for automated SMD assembly. Press-fit variants are mounted in polyimide, FR4, aluminum, and steel fixture plates with retention force >10 N axial. Retention housing strips and dual-contact pogo assemblies are available for high-density applications.
Spring Force and Travel Specifications
Pogo pin spring force is specified at three positions: free (unloaded) length, rated working position, and full compression. Working travel ranges from 0.3 mm (miniature pitch) to 5 mm (large industrial pogo pins). Spring rates from 0.1 N/mm to 5 N/mm. Over-travel protection prevents spring set and plunger damage. Spring material selection (stainless steel vs. gold-plated phosphor bronze) affects corrosion resistance and contact resistance of the spring-barrel interface at the back of the barrel.
Applications in Consumer, Industrial, and Medical Electronics
Pogo pin connectors are specified in wearable devices (smartwatches, fitness bands) for magnetic charging docks, medical devices for charging and data transfer ports, industrial PDAs and handheld devices for docking stations, and IoT modules for programming and testing interfaces. Related products include Brass Test Pins, Brass Header Pins, Brass Terminal Pins, Brass Plug Pins, and Brass Sockets For Pins for complete connector system design.
Key Features
- Three-component assembly: barrel, plunger, and compression spring
- Gold-plated contact surfaces (<20 mΩ initial contact resistance)
- Spring forces from 30 gF to 300 gF
- 1,000,000+ compression cycle life (ICT grade, Au plated)
- Miniature pitch from 0.5 mm; large power variants up to 8 mm diameter
- Press-fit, solder-tail, through-hole, and SMD mounting options
- Current capacity from 0.5A to 15A per pin
- RoHS and REACH compliant materials
Signal Integrity for High-Speed Applications
Coaxial pogo pins with signal and ground isolation provide 50 Ω impedance-matched contacts for high-frequency PCB testing up to 10 GHz. Low-inductance pogo pin designs minimize signal integrity degradation in high-speed digital and RF applications.
Medical Grade Pogo Pins
Medical-grade pogo pins use biocompatible materials and hermetically sealed barrel construction for implantable device charging interfaces per IEC 60601-1 and ISO 13485 requirements. Titanium, platinum, and gold materials are available for direct tissue contact applications.
Battery Contact Pogo Pins
Battery contact pogo pins for consumer electronics use large-diameter crowns (3–5 mm) with gold plating over nickel to handle charge/discharge currents up to 5A continuously. Spring forces of 100–200 gF ensure reliable contact with battery terminal pads across full temperature range from -20°C to +85°C.
High-Temperature Pogo Pins
High-temperature pogo pins with Inconel or beryllium copper springs operate reliably up to +200°C for automotive under-hood testing, reflow-compatible board testing, and industrial high-temperature environments.
Double-Ended Pogo Pins
Double-ended (dual-plunger) pogo pins make simultaneous contact at both ends and are used in PCB interposer fixtures, stacked PCB testing, and compression-mount connectors for backplane systems. Both plunger ends are independently spring-loaded for compliance in two directions.
Technical Specifications
| Parameter | Specification |
|---|---|
| Barrel Diameter | 0.5 mm – 8.0 mm |
| Overall Length (free) | 3 mm – 30 mm |
| Working Travel | 0.3 mm – 5.0 mm |
| Spring Force | 30 gF – 300 gF (at working position) |
| Barrel Material | Brass CW614N / BeCu C17200 |
| Plunger Material | BeCu C17200 / Hardened Brass |
| Spring Material | Stainless Steel 302 / Music Wire / PhBr |
| Plating | Gold 0.1–2 µm / Hard Gold / Nickel |
| Contact Resistance | <20 mΩ initial; <50 mΩ at 1M cycles |
| Current Capacity | 0.5A – 15A per pin |
| Operating Temp. | -55°C to +150°C (standard) / +200°C (HT grade) |
| Cycle Life | 100,000 – 1,000,000+ compressions |
| Price | US$ 11.50/kg |
Product Types and Variants
| Type | Description | Application |
|---|---|---|
| Standard ICT Pogo Pin | Press-fit barrel, crown or ball tip, hard Au plated | PCB in-circuit testing fixtures |
| SMD Pogo Pin | Surface-mount solder tail, T&R packaging | PCB-mounted charging contacts |
| Battery Contact Pogo Pin | Large crown tip, high-current Au plated | Battery charging interfaces |
| Coaxial Pogo Pin | 50 Ω impedance-matched, RF shielded | RF/microwave PCB testing |
| Double-Ended Pogo Pin | Dual plunger, spring at both ends | PCB interposer, stacked boards |
| High-Temp Pogo Pin | Inconel spring, rated to +200°C | Automotive, reflow testing |
| Medical Pogo Pin | Hermetically sealed, biocompatible | Implantable device interfaces |
Applications by Industry
| Industry | Application |
|---|---|
| PCB / EMS Manufacturing | ICT fixture, functional test, bed-of-nails |
| Consumer Electronics | Smartwatch/fitness band charging docks |
| Medical Devices | Implantable device charging, diagnostic interfaces |
| Automotive | ECU/BCM PCB testing, connector interfaces |
| Industrial Handheld / PDA | Docking station contacts, cradle connectors |
| IoT / Embedded Systems | Programming, JTAG, debug interfaces |
| Telecom | Module testing, SIM card contacts, M2M |
Manufacturing Process
Pogo pin barrels and plungers are CNC precision-turned from brass CW614N and beryllium copper rods on Swiss-type CNC lathes with ±0.005 mm dimensional tolerance. Plunger tips are precision-ground to the required tip geometry. Springs are coiled from stainless steel or phosphor bronze wire on CNC coiling machines with controlled pitch, outer diameter, and free length. Assembly is performed on automated spring-loading fixtures that insert the spring and plunger into the barrel and stake the barrel opening to retain the assembly. Gold plating of the assembled pogo pin is performed by selective plating or full-immersion plating in controlled cyanide gold baths per ASTM B488 Type II, Grade A. 100% electrical testing (contact resistance, spring force, travel) is performed on assembled pogo pins prior to shipment.
Quality Standards and Certifications
| Standard | Scope |
|---|---|
| ISO 9001:2015 | Quality Management System |
| ASTM B488 | Gold plating specification |
| IEC 60512-2-1 | Contact resistance measurement |
| IPC-9252 | PCB electrical testing requirements |
| IEC 60601-1 | Medical electrical equipment safety (medical grade) |
| RoHS 2011/65/EU | Hazardous substance restriction |
| REACH SVHC | Chemical compliance declaration |
Why Choose Electrical Accessories India
- Fully assembled pogo pins with 100% spring force and contact resistance testing
- Gold-plated precision plungers with <20 mΩ initial contact resistance
- 1,000,000+ cycle life available for high-volume ICT applications
- Medical and automotive-grade variants with full documentation
- Competitive pricing at US$ 11.50/kg
- Export to electronics manufacturers in USA, China, Germany, Japan, and 35+ countries
Frequently Asked Questions (FAQ)
Q1. What is a pogo pin?
A pogo pin (spring contact pin) is a spring-loaded electrical contact consisting of a barrel, plunger, and compression spring. It makes reliable temporary electrical contact through spring force compensation for mechanical tolerances.
Q2. What current can a pogo pin carry?
Current capacity ranges from 0.5A for 0.5 mm miniature pogo pins to 15A for large 8 mm power pogo pins. Derating is required at elevated temperatures.
Q3. How many cycles do pogo pins last?
Standard pogo pins: 100,000–500,000 cycles. ICT-grade hard gold plated pins: up to 1,000,000+ compression cycles.
Q4. What is the spring force of a standard pogo pin?
Spring forces range from 30 gF to 300 gF at working position. Specific force depends on application — ICT fixtures typically use 100–150 gF; battery contacts use 100–200 gF.
Q5. What pitch pogo pins do you manufacture?
We manufacture pogo pins for 0.5 mm, 0.8 mm, 1.0 mm, 1.27 mm, 2.00 mm, and 2.54 mm pitch applications, plus custom configurations.
Q6. Do you supply SMD (surface-mount) pogo pins?
Yes. SMD pogo pins with solder-tail bases are available in tape-and-reel packaging for automated PCB assembly.
Q7. Can pogo pins be used for charging interfaces?
Yes. Large-crown gold-plated pogo pins are widely used for magnetic charging docks, docking station contacts, and wearable device charging interfaces handling up to 5A.
Q8. What is the contact resistance of gold-plated pogo pins?
Initial contact resistance is typically <20 mΩ for gold-plated pogo pins, measured per IEC 60512-2-1 at 1A test current.
Q9. Are pogo pins RoHS compliant?
Yes. All our pogo pins use RoHS 2011/65/EU compliant brass, BeCu, stainless steel, and gold plating materials. REACH declarations available on request.
Q10. Do you offer double-ended pogo pins?
Yes. Double-ended (dual-plunger) pogo pins are available for PCB interposer and stacked board testing applications. Contact us for specifications.
International Terminology – Brass Spring Contact Pins (Pogo Pins)
| Language | Term 1 | Term 2 | Term 3 |
|---|---|---|---|
| Spanish | Pines de contacto de resorte de latón | Pogo pins de latón | Contactos elásticos de latón |
| Russian | Латунные контактные штыри с пружиной | Пого-пины латунные | Пружинные контакты из латуни |
| French | Broches de contact à ressort laiton | Pogo pins laiton | Contacts à ressort laiton |
| Portuguese | Pinos de contato com mola de latão | Pogo pins de latão | Contatos de mola em latão |
| Italian | Spinotti di contatto a molla in ottone | Pogo pin in ottone | Contatti a molla ottone |
Related Products – Brass Pins Category
- Brass Plug Pins
- Brass Sockets For Pins
- Brass Earth Ground Pins
- Brass Test Pins / Probe Pins
- Brass Header Pins / Male Connector Pins
- Brass Terminal Pins
- Brass Dowel Pins
- Brass Round Pins / Solid Pins
- Brass Hollow Pins / Tube Pins
- Brass IEC Appliance Inlet Pins
Request a Quote
📧 Email: sales@elecaccs.com | 📞 Phone: +91-22-43449300
📍 Plot 10, GIDC Industrial Estate, Jamnagar 361004, Gujarat, India