An Italian manufacturer of portable test instruments—including handheld multimeters, clamp meters, and calibration devices—was developing a new ruggedized model for field service technicians. The device required AA battery clips that could withstand frequent battery replacements, vibration during transport, and temperature variations from -20°C to +70°C.
The Challenge
The client’s battery compartment design used a custom PCB layout that required battery clips with specific dimensions:
Clamping force: 2.5N ±10% to ensure reliable contact
Contact resistance: ≤20mΩ
Material: Stainless steel 301 for fatigue resistance
Plating: Nickel for solderability
Quantity: 500 pieces for initial production
Standard battery clips from catalog suppliers either had insufficient clamping force or did not fit the compact PCB footprint. European suppliers quoted 6–8 week lead times with minimum order quantities of 5,000 pieces—far exceeding the client’s needs.
Our Solution
Tingfeng Hardware reviewed the client’s PCB layout and battery compartment drawing. We proposed custom AA battery clips manufactured from stainless steel 301 with the following features:
Optimized spring geometry to achieve 2.5N ±10% clamping force
Nickel plating (2–5μm) for solderability and 48-hour salt spray resistance
Tape-and-reel packaging for automated assembly
100% force testing on every clip
Our engineering team completed DFM analysis and tooling design in 5 days. We delivered 50 samples within 7 days for the client’s fit and force testing.
Results
The samples passed all fit and force tests. The client approved the design and we completed the 500-piece production run in 10 days—well ahead of the client’s production schedule. Every clip passed 100% dimensional inspection and force testing. The client has since ordered additional clips for two other instrument models.
Client Feedback
“Tingfeng’s custom AA battery clips fit our compact PCB perfectly. The force consistency was excellent, and the tape-and-reel packaging worked seamlessly with our automated assembly line. We have standardized on their clips for all our portable test instruments.”