Hybrid 3D printing of electrical connectors

Abstract

3D printing makes the low volume manufacture of smart and miniature electrical connectors practical. A hybrid electrical connector Additive Manufacturing (AM) process has been studied. The hybrid 3D printing platform integrates functions of component 3D printing, prefabricated component embedding and electronic circuit interconnecting. For connector polymer housing 3D printing, extrusion based 3D printing technology is most appropriate. Polymer housings made with other 3D printing technologies can also be pre-fabricated and used in the process. Robotic material handling systems place the pre-fabricated components, including metal contacts and PCB boards, into cavities of the connector housing before the cavities are fully closed. Electrical circuit traces are created by depositing conductive ink channels to realize electrical interconnections. Auxiliary functions including potting and curing are also needed to fulfill connector manufacturing requirements. Some electrical connector 3D printing applications have also been studied on a customized commercial machine platform.