Brass Terminal Pins

Brass Terminal Pins

Brass terminal pins are precision-machined male contact elements used in electrical connector systems, wire harness assemblies, PCB connectors, and terminal blocks. They are crimped or soldered to wire conductors and inserted into connector housings to form reliable electrical connections in automotive, industrial, telecom, and consumer electronics applications. Manufactured from free-cutting brass CW614N and phosphor bronze, brass terminal pins comply with IEC 60352, IEC 61984, and automotive LV 214 wire harness connector standards. Price: US$ 11.50/kg

Product Overview

Crimp Terminal Pins – Design and Function

Crimp terminal pins consist of a precision-turned contact pin body with a crimp barrel at the rear end. The crimp barrel is formed around the wire conductor and insulation using a calibrated crimp tool, creating a gas-tight mechanical and electrical connection. Crimp termination produces connections with pull-out force values per IEC 60352-2 and SAE USCAR-21. Crimp terminal pins are available in open-barrel (formed crimp) and closed-barrel (pre-formed tubular crimp) configurations. The pin mating end is machined to precise diameter tolerances (typically ±0.02 mm) for insertion into matching socket contacts.

Solder Terminal Pins

Solder terminal pins have a solder cup or solder pot at the wire termination end, into which stripped wire is inserted and soldered. These are used in applications where crimp tooling is not available or where soldered connections are preferred for reliability. Solder terminal pins are used in military, aerospace, and scientific instrument connectors where IPC J-STD-001 soldering processes apply. Pin-and-socket connectors with solder cups comply with MIL-DTL-24308 (D-Sub), MIL-DTL-28748, and IEC 60130-9 standards.

Wire Range and Contact Size

Brass terminal pins are available in crimp sizes for wire ranges from 28 AWG (0.08 mm²) to 10 AWG (6 mm²) conductors. Contact sizes are defined by connector families: size 20 (0.35–0.5 mm² wire), size 16 (0.5–1.5 mm² wire), size 12 (1.5–6 mm² wire) per MIL-DTL-38999 and equivalent IEC standards. Automotive connector pin sizes comply with USCAR-2 and LV 214 performance standards for wire crimp connections.

Contact Resistance and Retention

Brass terminal pin contact resistance is tested per IEC 60512-2-1 and IEC 61984. Initial contact resistance typically below 5 mΩ for tin-plated pins and below 3 mΩ for gold-plated contacts. Crimp retention force per IEC 60352-2 Test B exceeds minimum requirements for wire gauge across all pin sizes. Contact retention force (resistance to push-out from housing) per IEC 61984 Test 6b is typically above 30 N for size 16 contacts in standard connector housings.

Plating and Solderability

Tin plating (3–5 µm, matte finish) is standard for industrial and automotive terminal pins, providing solderability per IEC 60068-2-20 and corrosion resistance per IEC 60068-2-52 salt fog. Silver plating (3–5 µm) is used for high-current and high-frequency terminal pins where tin whisker risk must be eliminated. Selective gold plating on pin tip reduces contact resistance for low-force mating connectors. All platings are lead-free and RoHS compliant per 2011/65/EU.

Connector Family Compatibility

Brass terminal pins are manufactured to fit standard connector families including Deutsch DT/DTM, Amphenol Sine Systems, Molex MX150, TE Connectivity Econoseal/MATE-N-LOK, JST SM/SM2, and equivalent industrial connector families. Custom terminal pin profiles for OEM connector designs are produced per customer-supplied dimensional drawings with FAI and PPAP documentation. Related products: Brass Sockets For Pins, Brass Header Pins, Brass Plug Pins, Brass Terminal Blocks, and Brass PCB Connectors.

Key Features

• Precision CNC turned to ±0.02 mm contact pin diameter tolerance
• Crimp barrel for 28 AWG to 10 AWG wire range
• Solder cup / solder pot termination options
• Contact resistance <5 mΩ (tin), <3 mΩ (gold) per IEC 60512-2-1
• Crimp pull-out force per IEC 60352-2 and USCAR-21
• Tin, silver, gold plating options — RoHS compliant
• Compatible with major connector families (Deutsch, Molex, TE, JST)
• Custom OEM terminal pin profiles available

Automotive-Grade Terminal Pins

Automotive brass terminal pins comply with USCAR-2, LV 214, and IEC 62196 performance specifications. They withstand 1,000-hour salt spray (IEC 60068-2-11), 85°C/85% RH humidity (IEC 60068-2-78), and thermal shock -40°C to +125°C (IEC 60068-2-14). IATF 16949 documentation including PPAP, control plan, and FMEA available.

High-Current Power Terminal Pins

Large-body brass terminal pins for high-current applications (25A–100A) use heavy-wall tubular pin construction with tinned copper or brass alloy for EV charging, battery management, and power distribution harness applications. Contact geometry complies with IEC 62196-3 and SAE J1772 standards for EV charging connector terminals.

Mil-Spec Terminal Pins

Military specification brass terminal pins comply with MIL-DTL-24308 (D-Sub), MIL-DTL-38999, and MIL-DTL-26482 connector specifications. Manufactured to per-print dimensions with 100% inspection, PPAP documentation, and traceability to raw material heat number.

PCB Solder-Tail Terminal Pins

Vertical and right-angle PCB solder-tail terminal pins combine a mating pin at one end with a PCB-solderable tail, creating wire-to-board connector terminals. Wave-solderable and hand-solderable variants are available. Solderability per IEC 60068-2-20 Test T with steam aging conditioning.

Press-Fit Terminal Pins

Press-fit (compliant-pin) terminal pins for PCB backplane applications use a compliant zone that deforms elastically during insertion into PCB plated through-holes, creating a solderless gas-tight connection per IEC 60352-5. Press-fit force and retention per IEC 60352-5 test methods.

Technical Specifications

Material Grades

Product Types and Variants

Applications by Industry

Manufacturing Process

Brass terminal pins are produced on CNC Swiss-type turning centers and multi-spindle automatic lathes from precision brass rod stock per EN 12164 / ASTM B16. The contact pin end is precision-turned and ground to final diameter. The crimp barrel is formed with controlled inner diameter and wall thickness for correct crimp compression ratio per connector specification. All turned pins are deburred, cleaned ultrasonically, and electroplated. Crimp barrel geometry is verified using optical comparators and pin gauges. Full dimensional inspection reports and material test certificates accompany every production lot.

Quality Standards

Why Choose Electrical Accessories India

• Precision crimp barrel geometry for correct crimp compression ratio
• Automotive-grade documentation: PPAP, FMEA, control plan
• Compatible with all major connector families
• In-house plating with RoHS-compliant tin and gold platings
• ISO 9001:2015 certified; export to 35+ countries
• Competitive pricing at US$ 11.50/kg

FAQ – Brass Terminal Pins

Q1. What is the difference between a crimp pin and a solder pin?

A crimp terminal pin is mechanically compressed around the wire conductor using a crimping tool. A solder cup pin uses molten solder to bond the wire. Crimp connections are preferred in production environments; solder cups in repair and mil-spec applications.

Q2. What wire size do your brass terminal pins accept?

We supply terminal pins for 28 AWG to 10 AWG wire gauges. Crimp barrel dimensions are matched to specific wire ranges for correct crimp compression.

Q3. Are your terminal pins compatible with Deutsch DT connectors?

Yes. We manufacture terminal pins dimensionally compatible with Deutsch DT, DTM, and DTP connector families. Contact us with the exact Deutsch part number for confirmation.

Q4. What contact resistance do your brass terminal pins achieve?

Tin-plated brass terminal pins achieve <5 mΩ contact resistance; gold-plated contacts achieve <3 mΩ, measured per IEC 60512-2-1 at 1A test current.

Q5. Can you supply PPAP documentation for automotive customers?

Yes. We provide full PPAP Level 3 documentation including dimensional report, material certificate, control plan, FMEA, and MSA for automotive-grade terminal pins.

Q6. Do you supply press-fit terminal pins?

Yes. Compliant-zone press-fit terminal pins per IEC 60352-5 are available for PCB backplane applications.

Q7. What is the maximum current rating for your terminal pins?

Standard terminal pins handle 1A–25A. High-current power terminal pins for EV and power applications handle up to 100A per contact.

Q8. Do you provide samples before bulk orders?

Yes. Sample quantities of 100–500 pcs are available for engineering qualification prior to production orders.

International Terminology

Related Products

• Brass Plug Pins
• Brass Sockets For Pins
• Brass Earth Ground Pins
• Brass Test Pins / Probe Pins
• Brass Spring Contact Pins (Pogo Pins)
• Brass Header Pins / Male Connector Pins
• Brass Dowel Pins
• Brass Round Pins / Solid Pins
• Brass Hollow Pins / Tube Pins
• Brass IEC Appliance Inlet Pins

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📧 Email: sales@elecaccs.com | 📞 Phone: +91-22-43449300
📍 Plot 10, GIDC Industrial Estate, Jamnagar 361004, India

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