• * Electro Sheets
  • * Sample Connectors
  • * Pre-production Springs for Validation
  • * Prototypes and Smaller Batches in Contacts
  • * Smaller Batches in Cable-Shoes
  • * Prototype Busbars
  • * Sample Parts Brush Holder, etc. Mounted for Functional Tests
  • mechaSYS GmbH, Christinstr. 18, 75177 Pforzheim, Germany

20.04.2020 Assembly technology using laser welding

Spring and Contact connected by laser welding

Due to the tool concept, both parts are provided as bulk goods in the conveyor and positioned by means of robots and welded by means of lasers (laser welding technology).
The integral connection guarantees minimal contact resistance as well as consistent quality over the entire life time.

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 Concept Study

15.07.2019 Stamping/ Progessive Die Technology

Endless or strip sections, bending technology for rack electroplating or laser strips

A lack of skilled workers and increasing numbers in the prototype phase have led us to design and build a machine for endless belt and/ or strip sections.

This enables us to produce reliable small batches for our customers.

Laser cut for flexible customer requirements in cutting geometry, stamping and bending technology as in series production.

In addition: Everything naturally measured on our KEYENCE IM 6125 including statistical evaluation.

Typically quantities of 5,000 to 500,000 parts/ set per year.

Concept of Press and Contoll Unit

01.06.2019 Adjustment of customer-specific parts, EloPin feed in the pre-punching tape

Individual feed for multiple press-in zones with double plugs or in the comb
(executed here using EloPin)

  • Provision: Pre-punched press-in zone made from customer-specific pre-punching tape,
  • Laser-cut customer connectors:
    • Press-in zone from pre-punched tape measured on laser machine (to eliminate feed errors,...),
    • individual connectors laser-cutted,
    • Puzzle geometry at an individual distance of the press-fit zone,
  • installation of a second press-fit zone using a cutting plate in simple punching tool,
  • Laser welding of the second, installed press-in zone,
  • electroplating complete Ni, selective EloPin (Sn) and connector (Ag/ Ag),
  • bend and separate in strip tool (manual or automatic).

20.07.2018 CNC-Laser Welding Technology

Inhouse developed CNC-Laser Welding Machine

Increasing quality requirements in laser welding technology have prompted us to develop our own CNC laser welding machine.

Follwing: laser welding process of press-fit aeres in customer-specific distances.
Your advantage: No conversion costs for high-precision punching tools are required.

Left: welding including video. Right: CNC machine with XY table:

 Laser welding of press-fit pins for printed circuit board press-in technology (here exemplary: EloPin)          CNC Laser welding machine




01.03.2018 Raw-Material, Strip-Material Milled in Thickness

Stamping-Grids in Press-In-Technology


  • Milling on conventional milling machine, tolerances in thickness +/-0.015
  • Lasercutting out of pre-stamped strip-material (press-in area) - plating-strips
  • Coining of connectors
  • Plating both sides individual
  • Bending
  • Singulation

20.11.2014 Automotive

Connector-Modul in Press-In-Technology (Engine nearby Application)

from prototype (functional sample) to C-sample:

  • lasercutting out of pre-stamped strip-material (press-in area)
  • coining of connectors
  • Plating (Cu, Ni, Sn100 and Ag, passivated)
  • Molding (PBT GF30)
    (separation of contacts in molding toll integrated)

Connector-Modul in Press-In-Technology detail1

Connector-Modul in Press-In-Technology detail2

15.04.2013 Automotive/ Consumer

Pitch corrections in stamping part for press fit EloPin pitch from 5,08mm reduced to 4,0mm

Pitch corrections in stamping part for press

19.12.2011 Laser-Cleaning - Optimization of Parameters

Abrasion of Colophony on Top of AuCo0,3 - Contacts

Krypton-Fluorid-Excimer-laser (wave-length 248nm), electrical animanted;
Sequence of pictures: primitive state, cleaning 500 and 980 pulses past,
process time 2.8 sec.

Laser-cleaning - optimization of parameters

28.11.2011 Automotive

Start of Production for Brush-Holder-System:

Definition of reference standard in spring characteristic as well as project management until mass-produktion (SOP)

pictogram Start of Production for Brush-Holder-Systemdiagram 1  Start of Production for Brush-Holder-System











increase in productivity/ to limit consequences of machinery hazard incidents until Run@Rate:

diagram 2 Start of Production for Brush-Holder-System

02.11.2011 Consumer

Optimization of Laser Weld Seam for Consumer-Industry

Requirement to the overlapping seam:

no visibility of the seam after surface finishing on outer  shape
welding-partners each 1.4301 t=0.3mm

Optimization of Laserweld Seam for Consumer-Industry