3 mm Stroke Spring-Loaded Connectors

Mill-Max spring-loaded pins and connectors, often referred to as pogo pins or spring probes, are precision-machined interconnect solutions designed to maintain a robust electrical connection despite uneven mating surfaces, significant stack-up tolerances, and exposure to shock and vibration. A standout in their lineup features a maximum stroke of 3 mm (0.118"), providing the highest degree of compliancy in their current spring-loaded pogo pin offerings. This extended travel is crucial for applications requiring greater tolerance compensation in board-to-board or device-to-board connections, ensuring reliable connectivity even in assemblies subject to motion, such as portable or mobile devices that may use more flexible housings and materials.

Each spring-loaded pin is typically constructed from three precision-machined and gold-plated components [a plunger (or piston), a body, and a spring] assembled to provide the necessary range of movement. The gold plating over nickel on all components ensures excellent electrical conductivity, durability, and superior corrosion resistance throughout the product's life. The standard design is engineered to maintain a specified spring force at mid-stroke (e.g., 60 grams or higher), which is the recommended operating position for optimal electrical and mechanical performance. Mill-Max products are built for longevity, with some series rated for up to 1,000,000 cycles and rigorously tested to withstand a minimum of 50 g shock and 10 g vibration while maintaining continuous electrical contact. Available in discrete pins or connector strips, with options like surface-mount technology (SMT) or through-hole termination, these contacts offer an omnidirectional mating surface, simplifying blind-mate and quick-connect assemblies by eliminating the need for precise alignment and the insertion/extraction issues associated with traditional pin/receptacle systems.

Features

• 3 mm maximum stroke: highest compliance in the Mill-Max spring pin lineup for large tolerance compensation
• Precision machined components: ensures high-quality, low-resistance, and compliant connection
• Gold plating: provides excellent electrical conductivity, durability, and corrosion resistance
• High durability: rated for up to 1,000,000 compression cycles
• Shock and vibration resistance: tested to a minimum of 50 g shock and 10 g vibration
• Hard stop: incorporated to prevent over-compression and minimize spring damage
• Mid-stroke force: customizable spring forces available (e.g., 60 grams typical)
• Low contact resistance: as low as 20 mΩ maximum
• Current rating: typically 2 A continuous, 3 A peak per contact (varies by part)
• Tolerance stack-up compensation: ideal for bridging gaps and maintaining contact in multi-board assemblies
• Blind mate capability: omnidirectional mating simplifies assembly in restricted visibility
• Variety of termination styles: available in SMT, through-hole, solder cup, and crimp options
• Compact design options: allows for low-profile and fine-pitch spacing (0.050" or 2 mm centers)
• Target mating versatility: mates with PCB pads, target pins, or target connectors
• High-temperature thermoplastic insulators: suitable for SMT soldering processes (for connector strips)