Battery Contact & Terminal Contact Manufacturing

Custom Manufactured

With over 60 years of experience

Etchit manufactures precision battery contacts and terminal contacts for many demanding electronic applications. Our components are built for consistent performance, long service life, and optimal conductivity across industries including aerospace, medical devices, consumer electronics, and defense systems.

Whether you require standard geometries, custom configurations, or secondary processing to complete your project, our team produces battery contacts to your exact specifications with minimal tooling and efficient turnaround. Etchit is your trusted manufacturing partner for precision battery and terminal contact applications.

Our Capabilities

We provide complete print-to-production support for custom contacts, from customer-supplied designs through prototyping, manufacturing, and secondary operations such as forming, heat treating, and plating.

Our team works closely with customers to optimize parts for manufacturability, performance, and cost efficiency. We provide feedback on material selection, tolerances, and geometry based on decades of manufacturing experience.

Through photochemical etching and milling, we produce high-accuracy, tight-tolerance components with excellent repeatability, short lead times, and cost effective tooling. Etchit supports both low-volume and high-volume production programs.

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Material Selection

Material alloy and temper play a critical role in conductivity, durability, and long-term performance. Our team can provide guidance based on your specific application and requirements.

Common materials used in battery and terminal contact manufacturing include:

Beryllium Copper
Copper
Brass
Nickel Alloys
Stainless Steel
Phosphor Bronze

Secondary Services

Battery contacts often require forming and plating to meet performance, durability, and reliability requirements. While base materials provide structural and spring properties, plated surfaces create the stable electrical interface required for long-term reliability. Common plating options include nickel, gold, and tin. The appropriate plating method depends on the electrical, mechanical, and environmental requirements of the final application.

We partner with trusted vendors to provide quality secondary services including:

Precision Forming
Heat Treating
Plating

About Our Process

Battery contact flat blanks are produced using photochemical etching and milling, a chemistry-based process that creates burr-free, stress-free components with tight tolerances and excellent repeatability. This process is ideal for thin metals and intricate geometries where stamping or machining may introduce distortion or high tooling cost.

After inspection, flat parts move to the precision forming stage. Forming is performed using dedicated tool and die sets within pneumatic presses to produce consistent bends, spring features, and three-dimensional geometries required for final function.

Most applications require plating. Gold, tin, or nickel finishes are commonly applied to enhance conductivity, wear resistance, and corrosion protection. These processes are coordinated with our qualified suppliers.

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Frequently Asked Questions

What are typical tooling costs?

Photo-tooling used to manufacture the flat blank portion of a contact typically ranges from $250–$300 and can be used for multiple production runs.

Forming tool and die costs vary based on part complexity. Simple form tools may range from $400–$1,000, while more complex tools typically range from $1,000–$5,000. Geometry, tolerances, and number of forming operations will influence final tooling cost.

What tolerances can Etchit hold?

Tolerances depend on material type and thickness, but photochemical machining supports tight dimensional control and excellent repeatability. Our team can review your print and provide manufacturability feedback based on your requirements.

Does Etchit provide design services?

We do not provide product design services, but we offer design-for-manufacturability guidance based on our photochemical machining and forming experience.

Can Etchit support prototyping and production?

Yes. Prototype quantities can be produced for evaluation prior to full production, and we support both low-volume and high-volume manufacturing programs.