A manufacturer of voice-recognition data collection systems decided to replace its expensive connector with a customized connector— a pogo-pin design with a passive latching system — developed by an outside supplier. The data collection system manufacturer then asked its headset supplier to work with the new connector. And that’s when the headset supplier came to C&M for help.

This new connector had a molded boot (which is not very functional for this application) and a machined brass component (which was expensive to produce and was not the best fit for this application). We designed a pre-mold and an overmold to replace the molded boot. This delivered a water-tight seal along with a much greater straight pull strength. Though pull strength was not mentioned to us as an issue, we knew it was important because users of this equipment tend to disconnect cables by yanking on them, rather than by pulling the connector free. Too many pulls, and the connector would fail prematurely.

Our vast engineering expertise and deep industry experience helped us find the perfect customized solution for this connector challenge. The data collection system manufacturer ended up with a connector that is less expensive to produce, performs better, and withstands the rigors of daily use. The headset manufacturer ended up keeping a good customer. And C&M ended up with another great, long-lasting partnership.