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Production methods for AC mains power plug pins?

Engineering Asked by monkey on June 26, 2021

What are the production processes and steps involved in producing a mains powered device that plugs into a standard mains socket (like a smart plug for example). Mains plug pins are usually made of brass or steel, afaik. And for most countries, there is a plastic sleeve at the end of L&N pins to prevent fingers from reaching live pins as they are inserted / removed. This would require an insert to the injection mold.

Alternatively, since engineering is about lateral as well as brute force thinking, can you just buy brass plug socket parts of the shelf rather than manufacture them to order. How would this impact on the process?

Please elaborate with as much detail as possible!

One Answer

The AC power plugs vary a lot country to country. You will need to know how you plan to attach the pins to your circuit; ex wire solder cup, wire crimp, pcb surface mount solder, or pcb through hole solder. The exact manufacturing methods vary greatly based on those choices.

Unless you have unique requirements, I would definitely recommend sourcing pins rather than manufacturing them yourself. Alibaba is probably the best place to source ready made pins. Generally above $2000 order value the vendors will be able to do some customization.
Alibaba Vendor 1
Alibaba Vendor 2

Another nice thing about the vendors on Alibaba is that they generally share a video educating you on the manufacturing process. One shows the stamping process while the other shows the plastic over molding process.

Answered by ericnutsch on June 26, 2021

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