Integration of functionality and design in modern device concepts
In the development of modern devices for medical and industrial applications, the demand for space-saving, hygienic, and user-friendly connection solutions is growing. Conventional connectors are increasingly reaching their limits – particularly in terms of installation space, ease of use, and design integration.
We focus on magnetic connectors, which are seamlessly integrated into customer-specific plastic molded parts. This combination not only offers a compact design and intuitive handling, but also a closed, low-contamination housing surface – completely free of annoying gaps or protrusions.
Molding technology meets joining technology
Through the direct integration of magnetic plug-in systems in Plastic housing We create functional interfaces that fit perfectly into the overall design, both technically and visually. Whether color, geometry, surface structure, or feel – we design each molded part precisely according to your requirements.
To protect sensitive electronic components, we use our proven Hotmelt potting process It provides media-resistant sealing against moisture, dust, chemicals, and mechanical stress – ideal for demanding environments and economical series production.
Spring contacts with magnetic guidance
The heart of the magnetic plug-in systems are high-quality Pogo pins (spring contact pins)These ensure a low-resistance, vibration-resistant connection with a long service life. Depending on the design, current carrying capacities of up to 15 A per contact are possible – with a typical contact resistance of less than 100 mΩ.
We offer a wide range of contact options regarding:
- Spring force (25–900 g)
- Geometry and design
- Surface finishing (e.g. Super-AP for increased corrosion resistance)
This means we tailor each solution precisely to your electrical, mechanical and environmental requirements – ideal for medical technology, industrial applications and mobile devices.
Design freedom through integrated system solutions
The early integration of the connection solution into the plastic molded part not only simplifies assembly, but reduces the overall development and production effortAdditional functionalities such as LED displays, seals (up to IPx8), guides or locking devices can be embedded without additional effort.
The combination of plastic injection molding and magnetic connectors opens up new possibilities for engineers and designers: maximum design integration, improved user guidance and reduced complexity – while maintaining high functionality, reliability and technical precision.
Your effort remains minimal:
We only need information about the planned installation situation and the basic technical requirements – such as current strength, number of pins or protection class.
Based on this information, we will take care of the following for you:
- Conception and construction of the plug-in system
- 3D modeling and visualization for design coordination
- Design of magnetic force and spring contacts
- Cable assembly and integration into your assembly
- Prototyping using 3D printing
- Planning of series production including testing and logistics concept
This means you receive a tailor-made solution from a single source – tailored to your application, designed for easy installation and implemented ready for series production.
Brochure “Magnetic Plugs”
Advantages of integrated magnetic plugs at a glance
Technical advantages
- Compact design – ideal for mobile and space-critical devices
- Vibration-proof contacting through precise spring contacts (pogo pins)
- Self-centering thanks to integrated magnetic guide
- High protection class up to IPx8 possible
- Design freedom in shape, color and surface
- Additional functions can be integrated (LEDs, sensors, displays)
Economical advantages
- Reduced installation effort – no separate plug installation required
- Elimination of complex post-processing (e.g. gluing, welding, sealing)
- Series production with high process stability
- Complete solution from a single source – development, production, testing, logistics
User and process-related benefits
- Easy handling – contactless, intuitive, plug-in direction-free
- Comfortable release – ideal for frequent disconnection (e.g. charging, cleaning)
- Hygienic – no open sockets, easy to clean
- Diverse cable options – can be customized to suit the application
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