3D Printed Electrical Connectors: Types, and Companies Manufacturing them
Electrical connections play a crucial role in ensuring the smooth transfer of electrical impulses between various equipment. Depending on their design and termination ends, these connectors exist in numerous varieties, each of which serves a distinct purpose.
The development of 3D printing technology in the last several years has opened up new avenues for the production of electrical connectors. Learn all about electrical connectors—their many varieties, uses, and the latest craze: 3D printed ones—in this article.
Electrical Connector Types
1. Board-to-Board Connectors
These connectors allow you to connect PCBs (printed circuit boards) directly to each other, eliminating the need for cables. Because they take up less room than cable-based connections, these connectors are ideal for systems that are cramped. One kind of board-to-board connector is the mezzanine connector, which allows for the parallel or perpendicular stacking of printed circuit boards (PCBs). Separability, mechanical needs, and environmental considerations are all aspects to think about while selecting these connectors.
For instance, the FX27 Series FunctionMAX floating, card-edge board-to-board connector from Hirose; Mill-Max's parallel board-to-board connectors; and Ironwood Electronics' custom board-to-board connectors.
Computer and telecommunication systems frequently employ backplane systems, which consist of a series of parallel ports. Backplane systems with high signal integrity are required for high speed applications, which means connectors need to be durable enough to withstand many insertion and removal cycles, have good impedance matching, and shield well. STRADA Whisper backplane connections from TE Connectivity is a good example.
2. Wire/Cable-to-Wire/Cable Connectors
A wire-to-wire connector joins two wires by means of a permanently attached end and a detachable interface; this type of connector is also known as a cable-to-wire connector. Insulation displacement contact (IDC) is a superior method of connection than crimping due to its mass termination and wire management advantages.
Consider the 53-8702 IDC/Press-Fit WTB connections made by AVX Corporation, which are ideal for use in automobiles.
3. Wire/Cable-to-Board Connectors
Wire-to-board connections link cables or wires to printed circuit boards. The insulation displacement contact (IDC) benefits are making a move away from press-in or soldered two-piece connections and towards cable-to-board connectors, which are the most common type of these connections.
Despite the versatility of wire-to-board connectors, cable assemblies are quickly becoming the preferred method of utilising IDC technology in the industry.
Electrification and the Need for Advanced 3D Printed Connectors
Although new entrants like Tesla have paved the way, established manufacturers are also making significant contributions to the transition to electric vehicles. With the growing importance of electronic interconnection, there is a constant need for novel solutions, particularly in the field of electrical connectors.
The movement towards electrification is spreading beyond just passenger cars. Automakers are adding more and more computer systems, accessories, and technological features to vehicles, and it's not just EVs. Furthermore, new markets are about to open up, like delivery drones and autonomous robots. These innovations call for cutting-edge electrical interfaces to back up a solid foundation. Manufacturers of a diverse array of products in lower quantities have presented TE Connectivity, Aptiv, Molex, and Amphenol—long-standing names in the connector industry—with the formidable task of adjusting to this new market reality.
Challenges in Using 3D Printing for Connections in Electrical Systems
3D printing has obvious promise for improving electrical connector manufacturing, but there are still obstacles to overcome. Lambert highlights the importance of material characteristics and print resolution in preventing the broad use of 3D printing for connections.
Constraints on Materials
Most common car electrical connectors use PBT, PPS, or nylon, which are engineering-grade thermoplastics filled with glass. 3D printing PBT or PPS is not now possible, which is a major setback. 3D printed nylon has been around for a while, but it still can't quite satisfy the needs of commercial multi-cavity electrical connectors. Printing with common thermoplastics is a challenge for DLP and SLA systems, even if they can reach the required resolution.
Problems With Print Resolution
The physics of FDM and SLS, two prominent commercial thermoplastic additive manufacturing methods, impose constraints on commercial electrical connectors in terms of resolution, surface polish, wall thickness, hole size, and tolerance requirements. The demanding specifications of electrical connector applications necessitate better resin formulas, notwithstanding the encouraging results achieved with DLP and SLA.
Companies Manufacturing 3D Printed Electrical Connectors
1. Samtec
Leading 3D connection company Samtec is well-known for its premium goods and creative ideas. Their connectors satisfy a wide spectrum of uses, including industrial automation and data centres, and are quite dependable. Professionals seeking reliable 3D connectors prioritise this organisation due to its commendable technical assistance and customer care.
2. TXGA
Focusing on price without sacrificing quality, TXGA provides a large range of 3D connectors. TXGA's products enjoy high respect for their accuracy and robustness, making them suitable for a variety of electronic applications. Companies seeking reasonably priced solutions highly value TXGA's fast delivery times and first-rate customer care.
3. TE Connectivity
TE Connectivity, renowned in the connector sector, offers modern 3D connectors. Emphasising quality and creativity, they make sure their goods satisfy the most exact criteria. The automobile and aerospace sectors find significant applications for their connectors. The worldwide presence and outstanding knowledge of TE Connectivity make it a dependable partner for difficult projects.
4. Fortify
Although Fortify is a recent participant in the 3D connection scene, its sophisticated manufacturing methods have drawn quick interest. Their areas of expertise include designing strong, high-performance connectors with original materials and techniques. Companies seeking modern 3D connector solutions can definitely consider Fortify because of their dedication to quality assurance and creativity.
3D Printed Electrical Connectors: 3 Best Options
1. Power Connector Housing
Introducing our Power Connector Housing, an affordable way to remove electrical components without needing tools. It efficiently links power lines and is suitable for low-voltage DC applications due to its 30 Amp rating. This connector, which is ideal for Kossel delta printers and comes with a secure housing mount and M4 hammer T nuts, can be purchased from Digi-Key, Parts Express, Amazon, or for a more reasonable price (< $2.50 USD per pair) on AliExpress.
For all of your networking needs, this revolutionary design guarantees that industry standards are satisfied, allowing for low-volume manufacturing that is rapid, efficient, and cost-effective.
Download Link: Cults.
2. Battery Connector for Milwaukee M18
Introducing our 3D printed Battery Connector, a game-changer for accessing Milwaukee M18 18V batteries. Designed to clamp snugly onto the battery, this set up makes use of automotive-grade 3mm red blade connectors for a solid electrical link.
The use of PLA+ and PETG in its printing process guarantees long-term stability. This design showcases the versatility of 3D printing technology by incorporating mounting hole overlays. It gives a clean and efficient solution.
Download Link: Thingiverse.
3. Wago 221 Connector Universal Mount
Our universal mount for Wago 221 connectors makes electrical connections easier; it can hold two-, three-, or five-way connectors. It is simple to remove and reinstall, and it has a positive "clip" sound to ensure a snug connection. This mount guarantees functionality with its 6g (3.5mm) countersunk mounting screw hole and aperture for rear access testing.
Prints well in both PETG and PLA+, giving you options for materials that solve real-world problems with electrical connection. This design is compatible with a wide range of 3D printers and offers a simple yet effective way to attach Wago 221 connections to base plates.
Download Link: Thingiverse.
4. Electric Wire Connector
Henry Wang's practical tool, the Electric Wire Connector, is meant to link two wires without soldering. This is especially useful for simple and rapid electrical connections. Usually printed using PLA filament, the connector might have better performance and durability by utilising nylon filament. One M3 washer is needed in the design to run as intended.
Experts and enthusiasts alike love this connector because its simplicity and ease of use define it. On YouTube, you can discover comprehensive information and directions on how to use this connector, so that even beginners may make good use of this instrument.
Download link: Myminifactory.
5. Lever Wire Connector Mount (Parametric)
Designed by The One True Patrick, the Lever Wire Connector Mount is a strong and flexible fix for inline wire connections. With all measurements included in Fusion 360's User Parameters, this mount is quite customisable. This function lets users change the mount to suit their specific requirements, allowing for different manufacturer standards. One can adjust the "TerminalCount" value to enlarge the mount for the needed quantity of connectors.
Though it has only been tested for up to six terminals, the design guarantees simple printing with a 0.4mm round over on the edges, therefore removing the need for supports or brums. Printed using Orca's default "0.2mm Strength" settings with Bambu PLA Basic, the mount is robust and dependable. Printing a batch of 11 takes roughly one hour; hence, this is a quick solution for several uses.
Download Link: Printables.
Having looked at 3D printed electrical connectors, it’s also important to have a look at the best 3D printing software that you can use to create your 3D models and even prepare them for 3D printing. There are many that are available, but we recommend using SelfCAD.
SelfCAD is one of the easiest 3D modeling software useful for creating both simple and complex 3D models. It comes with various tools like freehand drawing and sketching, image to 3D model, powerful 3D sculpting brushes, and powerful deformation and modification tools. The video below shows how SelfCAD works.
In addition to 3D modeling tools, SelfCAD also comes with an in-built online slicer that you can use to slice your files and generate the G-code to send to your 3D printer. Learn how to slice STL files in SelfCAD in the video below.
The software also comes with many tools for learning, including SelfCAD academy, many interactive tutorials, and YouTube videos like 3D modeling tutorials for beginners and 3D modeling 101 series that you can use to learn how the software works.
Enjoy powerful modeling, rendering, and 3D printing tools without the steep learning curve.
Need to learn 3D modeling? Get started with interactive tutorials.