Custom Brass Electrical Connector Parts for a New Energy Storage System

A growing energy storage company asked us to produce 3,000 custom brass electrical connectors for their new residential battery storage system. The parts required tight dimensional tolerances to ensure proper electrical contact and good conductivity.

Brass is a tricky material to machine, often causing burr formation on edges that can affect assembly and electrical performance. The client required consistent quality across 3,000 parts at a competitive price.

We optimized our cutting parameters for brass, using sharp carbide tools and selecting the right cutting speeds to minimize burrs. We also implemented a secondary deburring process to ensure clean and smooth edges. The production run was handled on a CNC turning center, allowing efficient production while maintaining consistent tolerances.

We worked with the client to modify the design slightly to make it more manufacturable, reducing production costs without compromising performance.

We delivered the full order of 3,000 parts on time, 12% under budget. The client reported zero quality issues in assembly and has already reordered 5,000 more connectors for their next production phase.