High precision stamped parts in loose-piece or strip-fed form, bright, pre-finished or fully or selectively electroplated following production. Production takes place on ultra-modern automated stamping presses working at up to 1,500 strokes per minute and, some of which produce over 500 million parts a year. Application in the automotive and electronics industry. Especially E-Mobility and press-fit technology.

specialty

• Plugs and connectors, reel to reel, selectively electroplated
• Variety of combination tools
• BIZON® Press-fit-zone
• Assembly in the progressive tool
• Reel-to-Reel

Equipment

• High-performance stamping presses with up to 1,500 strokes/minute
• Press force 200 up to 1.600 kN
• Strip width 6 to 200 mm
• material thickness 0,1 to 3,0 mm

ZETKA supported its customers with prototypes and small series from the very first electrically powered vehicles.

The experience we have gained in this way gives us a knowledge advantage and enables us to ask the right questions in order to precisely determine customer needs.

The use of special Lean-Tool stamping and bending tools for our Bihler GRM-NC system allows us to produce busbars with a material thickness of up to 4 mm in a cost-effective and material-saving manner, depending on the geometry.

We usually optimize these with our customers in order to achieve the highest possible process reliability. More complex busbars, on the other hand, are manufactured on our stamping machines using modular progressive dies.

With both production concepts, we are able to produce both small series and large series.

In the development process, however, laser or micro water jet cut prototypes or pre-series are used. The completion with press-in threaded bolts or press-in nuts as well as the use of insulating foils or hoses usually takes place in a subsequent operation, independent of the stamping process. This also allows us to carry out mechanical or galvanic post-treatment.

For optimal further processing, we use product-specific blister packs or deliver the parts as tapes, as long as the material thickness allows.

The materials used are sourced exclusively from European plants. If necessary and required, the material is pre-processed or the individual parts are treated using frame electroplating.

Easily assembled, maximum added value – all on a one-stop-shop basis

Assembling components is one of our core competences. No matter whether an assembly consists of several stamped parts or is a combination of stamped part, turned part, cold-headed part, milled part, contact rivet, cable, wire, plastic component or standard part, we are the experts in fully automated component assembly with the aim of supplying our customers with a ready-to-install assembly or a complex system on a just-in-time basis for a variety of end uses. In many cases, this is where we only need a single-stage production cycle in combination with the stamping process.

Overmoulding of stamped parts, stamped grids or stamped strip for the production of high-quality hybrid components complement the range of activities covered. As early as the development phase, we optimise the tolerance ranges of stamped parts to the necessary plastic-compatible minimum, thereby maximising quality far beyond the level required and demanded by the customer.

In combination with BIZON® press-fit contacts, hybrid housings are produced that permit trouble-free assembly of the printed circuit board in the downstream, follow-on process.

To assemble small-volume batches, we set store by tried and proven manual assembly or semi-automatic processes as well as the experience and dexterity of our staff.

A press-fit zone with particular flexibility

We can give you broad-ranging design flexibility in terms of material selection, material thickness, material strength and adaptability to your specific needs and technical requirements. Made to measure exactly to the customer's needs. Providing BIZON® press-fit technology, ZETKA offers an innovative solderless contacting system for all requirements in the automotive supply industry, electrical engineering, power electronics and any other application where secure contact connection to a printed circuit board or metal plate defines the quality of the final product.

Solder-free, robust and secure

This press-fit technology is a solder-free, robust, secure electrical connection technology in which preferably elastic, formable pins are connected into metallised (copper-plated) printed circuit board holes with defined dimensions at a defined speed using a press-fit facility. This produces a permanent gas-tight mechanical and electrically low-resistance connection (cold welding) at the contact surfaces between the press-fit pin and the hole's metallic inner wall. The unique spring properties of the BIZON® press-fit contact prevent any damage to the printed circuit board if the press-fit process is carried out correctly, thereby preventing delamination (whitening) and tearing of the inner layers.

Press-fit technology for high-current applications with optimised maximum contact surface

The key aspect and major benefit of BIZON® press-fit technology lies in providing the greatest possible square cross-section with accurate self-centring in the PCB hole. The conductor cross-section this achieves is approx. 72% of the hole cross-section, permitting a high electrical strength per contact. With its four defined contact areas, each BIZON® contact provides maximum contact surfaces and, as such, outstanding and secure contact properties. This provides the capability of safely handling several hundred amperes with standard 75 µm printed circuit boards (70 A per contact, hole 2.0).

This is a key cost advantage for any high-current application. Depending on the application, you can avoid unnecessary cost and time-intensive surface finishes in the press-fit zone by using bare BIZON® contacts. This prevents the formation of whiskers and tin chips which can lead to failure of the entire assembly down the line. The contact can be produced in any size and sheet thickness of any material you choose. Exact harmonisation with your particular application can avoid the need for expensive special materials by using standard materials. Let us show you the options and limits.