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Custom Connector Design

CUSTOM ENGINEERED CONNECTORS

iCONN Systems is equipped with the ability to solve all of your custom connector design and interconnect needs. Some applications require a full cable assembly and connector design, where we take our customers through our Custom Engineered Process and develop a product from the ground up. Some applications are less stringent and need a standard off the shelf connector. iCONN Systems excels in both!

Below are some real-world examples of custom connectors that we manufactured to meet our client's specific needs.

Designed & Built to Last

Problem:

Customer needed a connector to withstand 500 lbs of straight pull force, while incorporating a 30 awg coax wire

Solution:

iCONN designed and developed a solution that included:

  • Custom Geometry for coax, signal and power
  • Self-cleaning threads for an extremely dirty (sewer) application
  • Custom cable construction with strength members
  • Specific resins for mechanical bonding and sealing

Zero Defects in Harsh Environments

Problem:

Customer needed a product to survive in burning buildings - people's lives at stake.

Solution:

iCONN developed a repeatable process to build robust assemblies with zero defects in application.

Robust & Aesthetically Pleasing

Problem:

In application, the Customer's solution was not aesthetically pleasing or robust.

Solution:

iCONN developed a robust assembly method using a custom overmold on titanium housings. Marketing had a visually appealing product for an easier sell.

3D Printing for the WIN!

Problem:

Customer was experiencing field-failures due to a previous custom design.  The current supplier did not factor in the application environment.

Solution:

iCONN designed and printed prototypes for field testing to win the business and prove that our design would survive.

Sealing and Connectorizing Battery Cases

Problem:

The customer needed a low profile battery housing that would allow the end-user to replace batteries, remain sealed and meet industry regulations.

Solution:

iCONN designed and developed a battery housing to fit within the given real estate, and used a custom overmolding process to ensure everything is water-tight.

Sensitive Circuitry Sealed

Problem:

The customer needed a sensitive PCB sealed in a cable assembly - and needed it in 3 weeks!

Solution:

iCONN's low pressure overmolding capability and quick-turn tooling program delivered product to the customer cost-effectively and on-time.

Sealed PCB Mount Connector

Problem:

Customer needed a PC Board mounted connector that would also seal when installed into their product housing.

Solution:

iCONN designed a connector that could be wave soldered to a PC board and create a watertight seal when installed into the housing.

Low Profile I/O Connector

Problem:

Customer needed a low-profile connector capable of handling 16 positions and a standard off-the-shelf item was not available.

Solution:

iCONN designed and tooled a connector to minimize overall height of product while maintaining an IP67 rating.

Seamless Connector Integration

Problem:

Customer wanted a connectorized end cap for a light bar that meshed with the size and geometry of their light bars.

Solution:

iCONN designed an end cap overmold with an integrated connector.  This end cap sealed the entire light bar from outdoor elements.

Cheap! and Custom

Problem:

Customer needed a cheap, high-volume connector to carry power from unit to unit in series.

Solution:

iCONN designed cheap, yet robust contacts for this connector, and automated assembly equipment to meet high volume demand.

Quick-Connect PCB Mount Connectors

Problem:

Customer needed a connector that mounted to a PC board and would have many sensor replacements.

Solution:

iCONN designed a quick-connect / disconnect solution that would simplify sensor changes for the end-user.

Quick Connect IP67 Connector

Problem:

Customer needed a low-profile connector capable of handling 16 positions and nothing off-the-shelf would work.

Solution:

iCONN designed and tooled a connector to minimize overall height of product while maintaining an IP67 rating.

Ready to discuss your project and custom needs?

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Custom Connector Manufacturer

iCONN is a leader in new product development. With a team of skilled engineers, our custom connector design strategy can be tailored to your needs. We’re able to walk you through the process and go over the details ahead of implementation to help you avoid a costly mistake. We carefully consider the guidelines of the applications to make sure they meet the required specifications.

Custom Cable Connectors

iCONN’s custom cable connectors are developed in-house. We understand that not all applications are the same, and off-the-shelf connectors can limit design intent and product functionality. We work with your team to develop and manufacture specifically engineered solutions.

CONTACTING CONSULT

iCONN Systems provides custom-designed, application-specific connectors and cable assemblies. We understand that off-the-shelf products can limit your designs, and that not all applications are the same.

Then let iCONN walk you through the process to develop the product that fits your budget and application. Fill out the form to the right to request a consultation today.

Do you need an interconnect solution that is:
  • WEATHER-RESISTANT
  • FIREPROOF
  • HEAT-RESISTANT
  • WATER-RESISTANT?

What can we help you with?