Power terminals are metal devices that connect a power wire or cable to a device, so electricity can flow from a power source into the device. They are generally stamped from conductive metal such as copper or brass, and can be designed in a variety of shapes and configurations to suit the need of an application.
Precision stamping is an efficient and cost-effective way to manufacture metal parts like terminals. Computerized drawings of parts are used to create tooling that reproduces each part feature within the acceptable tolerance specified. Because the same tooling is used over and over, there is little variation between parts, and because the stamping presses work quickly, cycle times are short.
G&M Manufacturing is a trusted precision stamper, providing custom power terminals for use in electronics, automotive, medical, electrical, telecommunications, and other industry applications. Learn more about our work and some common uses for terminals below.
G&M’s Custom Power Terminal Manufacturing Expertise
At G&M Manufacturing, we specialize in precision metal stamping for customers who need dependable, high-performance components. Our stampings are used in many applications in the automotive, electronics, medical, and other industries.
Electrical terminals can be designed in a number of ways, depending on the application, the voltage and current involved, and the size limitations of the other components in the electrical system. Because the main job of a terminal is to connect the power source to the electrical system, materials must have low resistance to enable a steady flow of current. Copper and bronze are common choices, and these can be plated with tin or nickel to enhance conductivity and prevent corrosion.
There are multiple types of connection point designs as well, including screws, springs, clamp, crimp, push, and plug connections to hold wires in place securely. Groups of terminals can also be installed in a unit called a power terminal block, which allows for multiple connections in a single unit for power distribution.
Achieving proper fit is critical in power terminal manufacturing, because fit directly affects how the component functions and how well it holds the wires in place. Precision stamping is a common choice for terminals because it is a highly repeatable, low-variation process, and because of its ability to create detailed part features and to hold tight tolerances throughout a production run.
An Example of Our Custom Power Terminal Stamping Capabilities
An example that illustrates our capabilities and production capacity is an automotive blade terminal used in a power circuit for an interconnect header. We use progressive stamping equipment to produce over 1.5 million of this component annually, meeting tight production schedules without compromising on quality. Here are the details of production:
- Part dimensions: 49 mm long x 22 mm wide.
- Material: C14415 high-performance copper, with extra-hard R420 temper and 1.2 mm thickness.
- Allowable tolerance: ±0.025 mm.
- Equipment used: 60-ton Bruderer straight side punch press.
- Finishing process: Reflow tin finish over a copper flash layer for optimal conductivity.
- Quality assurance: Inspected with our Zeiss O-Inspect system.
Power Terminal Applications
Power terminals provide essential electrical connections and support power distribution in a variety of commercial, industrial, and consumer products. Common applications include:
- Industrial Automation: Control panels, robotic arms and end-of-arm tools, variable speed drives.
- Machinery: Motion control units, motors, fans, blowers, refrigeration units.
- Lighting Systems: Indoor and outdoor LED lighting, onboard lighting in vehicles and equipment.
- Automotive and Transportation: Battery connections, wire harnesses, motor systems, entertainment systems, window motors.
- Power Distribution Panels: Groups of stamped terminals can be assembled in terminal blocks to simplify branching power inside control cabinets and junction boxes.
- Printed Circuit Boards (PCBs): Press-fit or soldered power terminals.
- General Electrical Wiring: Grounding connection points.
Dedication to Quality
With over 40% of our products shipped globally, G&M Manufacturing has built a reputation for excellence in stamping with international reach. We produce custom power terminals that meet our customers’ requirements for materials, conductivity, fit, and function.
To deliver the highest-quality stampings, we prioritize early-stage planning, clear communication about design intent, and quality assurance and inspection. Tooling is designed and built in-house and is guaranteed for the life of your program.
Contact G&M Manufacturing for Custom Power Terminals
No matter the industry or application, custom power terminals are needed for safe and reliable connections in vehicles, equipment, and devices. G&M’s stamping capabilities and experience mean we can bring your design to life with high precision and short lead times.
Contact us to learn more about our process and stamping operations, or request a quote to discuss your next power terminal project.