Two Metal, Two Plants, One Reel: Appliance Timer Contacts Assembled In-Die

An appliance timer control builder was staging two suppliers: brass springs from one, silver contact rivets from another, and a manual riveting cell of its own. At 300,000 pieces per release, the assembly labor quietly exceeded the hardware cost.

We made the assembly disappear. Terminal, blade, and contact designed together in CAD, silver contact riveted into the brass spring during the stamping run, and the finished sub-assembly leaving the press ready to drop into the timer. Pre-tinned brass (0.8 mm) plus 0.38 mm copper spring, 100% tin dip finish for corrosion resistance on the contact faces.

Outcome

• 300,000 assembled contacts per release, JIT against the timer line schedule
• Tightest dimension ±0.005 mm including the rivet seat
• Riveting cell off the customer's floor; one purchase order replaces three
• Silver contact in-process assembled — no separate inventory to manage

Specifications

pre-tinned brass + #194 copper + silver rivet · 0.8 mm / 0.38 mm · multi-material in-die assembly · DWG print standard · MOQ 10,000