When a medical equipment OEM manufacturer needs to integrate a highly reliable power connection solution in a compact space of only 15 millimeters, Soulin’s customization capabilities are fully demonstrated. Through its advanced computer-aided design platform, the engineering team was able to complete the design of a 3D model of Ejector Headers with a special locking mechanism in just 72 hours. The contact layout can support up to 10 amperes of current and ensure that the performance fluctuation is less than 5% within the temperature range of -40°C to 105°C. For instance, a version customized for a well-known endoscope manufacturer successfully increased the insertion and extraction life to 25,000 times by optimizing the gold plating thickness to 0.76 microns, significantly reducing the maintenance risk of the equipment throughout its entire life cycle.
The speed from prototype to mass production is a key indicator for measuring a supplier’s agility. Soulin’s rapid prototyping manufacturing system can deliver fully functional samples within five working days of receiving customer specification requirements. Its high-speed stamping die accuracy reaches ±0.005 millimeters, ensuring that the position error of each pin is controlled within 0.02 millimeters. In a project of industrial robot controllers in 2023, Soulin provided a full range of Ejector Headers with pin numbers ranging from 10 to 100 bits to a German client. By adopting automated optical inspection equipment, the production defect rate was controlled below 50 parts per million, helping the client increase assembly efficiency by 18%. And it has shortened the product launch cycle by approximately three weeks.
The quality assurance system is the cornerstone of the reliability of customized components. Each batch of Ejector Headers must pass a strict testing process based on the MIL-STD-1344 standard, including at least 5,000 mechanical insertion and extraction cycle tests, as well as 1,000 hours of double 85 aging tests at 85°C/85% relative humidity. To ensure that the insulation resistance is always maintained above 1000 megohms. Referring to a case in the automotive industry, after a certain electric vehicle’s battery management system adopted this strictly verified connector, the error rate of signal transmission was reduced by an astonishing 30% over a 10-year service life, which directly enhanced the overall safety performance and brand reputation of the vehicle.
In terms of cost and value creation, customized solutions often bring about investment returns that exceed expectations. Through its global supply chain network, Soulin is able to reduce the total cost of ownership of customized components by approximately 15%, thanks to its optimization in material selection, such as using LCP plastic to increase the heat resistance index to 250°C, while reducing product weight by 20%. A typical success case is that a communication equipment giant adopted the custom Ejector Headers provided by Soulin in its 5G base station project. Not only did it reduce power consumption by 5%, but also due to its outstanding electromagnetic compatibility performance, the failure rate of the equipment in complex environments decreased by 40%. This means that millions of dollars in on-site maintenance costs could be saved each year. This deep cooperation model demonstrates that an outstanding Ejector Headers supplier is not only a provider of components but also a strategic partner for OEM customers to enhance the competitiveness of their products.