High Current Pogo Pin
Pexon Professional Customization
High Current Pogo Pins
Spring Loaded High Current Pin Catalog
High current pogo pin, also known as spring loaded high current pins, high current spring contacts, or through hole spring loaded high current pins, are primarily used to establish reliable electrical or signal connections between components. They ensure consistent conductivity and stable contact performance in various electronic applications.
High Current Pogo Pins Overview
High Current Pogopin Product Details
With advanced technology and expert craftsmanship, we create durable, high performance custom high current pogo pin / high current spring connector pin tailored to each project’s needs.
What is a high current pogo pin
High current pogo pin is a spring loaded electrical contact designed to carry relatively large amounts of current while still allowing repeated, reliable connections. It typically consists of a plunger, spring, and barrel, and maintains contact force through the internal spring. “High current” versions are engineered to reduce contact resistance and heat buildup by using a larger pin diameter, a bigger contact area, stronger spring force, and low resistance materials with suitable plating (commonly gold or silver). They are widely used in charging docks, battery contacts, test fixtures, industrial connectors, robotics, and other applications where quick connect/disconnect is needed. Key selection factors include continuous current rating, contact resistance, allowable temperature rise, stroke and working travel, mechanical life (mating cycles), vibration tolerance, and environmental requirements such as corrosion resistance.
How to install high current pogo pin
To install a high current pogo pin, first confirm the pin’s current rating, stroke, and mounting style (PCB mount, press fit, or housing mount). For PCB mounting, follow the footprint drawing, ensure correct hole size and plating, and keep copper traces wide with short paths to reduce resistance and heating. Solder carefully using the recommended temperature profile to avoid damaging the spring mechanism; avoid excessive dwell time. For press fit types, use the specified insertion force and a flat, guided press tool so the barrel is not bent. If mounting in a plastic or metal housing, ensure the pocket depth matches the pin length and working travel, and provide firm mechanical support. Finally, verify alignment with the mating pad, measure contact resistance, and test under load for temperature rise.
high current pogopin material & parts
High current pogo pin typically has three main parts: plunger (tip), spring, and barrel (housing). The plunger and barrel are often made from brass or copper alloys for good conductivity, sometimes beryllium copper for strength and springiness in the tip. The spring is usually stainless steel or music wire for fatigue resistance. To lower contact resistance and prevent corrosion, surfaces are plated most commonly gold over nickel for stable, low oxidation contact, or silver when very low resistance is needed (but it can tarnish). High current designs may use a larger diameter, thicker walls, and stronger springs to maintain contact force and reduce heating.
high current pogopin Internal structures
high current spring loaded contacts commonly use three internal structures. (1) Plunger bevel structure: the plunger tip has a beveled face that guides contact, increases effective touch area, and helps reduce contact resistance under load. (2) Plunger bevel + steel ball structure: a small steel ball is integrated at the contact point to provide rolling/self cleaning action, improving stability and wear performance during repeated mating while maintaining low resistance. (3) Plunger inner hole bevel structure: the plunger includes an internal beveled hole that improves alignment and pressure distribution, supporting higher current by lowering localized heating and enhancing mechanical reliability. These designs target better conductivity, durability, and consistent contact force in high power applications.
How high current pogo pins work
High current pogo pins work by using a spring loaded plunger to maintain steady contact pressure against a mating pad or pin, even with vibration or slight misalignment. When pressed, the plunger slides into the barrel, compressing the internal spring. This creates a consistent normal force that breaks through light surface films and keeps contact resistance low. Current flows through the conductive path formed by the plunger, spring interfaces, and barrel into the PCB or cable connection. High current designs reduce heating by using larger diameters, smoother contact surfaces, stronger springs, and highly conductive materials with gold or silver plating. Proper alignment and sufficient working travel ensure stable contact and long mating life.
High Current Pogo Pin Contact Resistance
This chart illustrates that during the full compression and release stroke of the high current pogo pin, the spring force increases smoothly while the contact resistance remains extremely low and stable. This demonstrates a well engineered internal structure, precise machining tolerances, and high quality vacuum blind hole plating that together ensure reliable electrical connectivity and long term performance stability.
types of spring loaded high current pin
Custom Guide of High Current Pogo Pin
Select high current pogo pins based on travel length, spring force, contact material, and plating to achieve optimal performance, reliability, and durability.
Fully customizable to meet any electrical, mechanical, or environmental requirements.
| High Current Pogo Pin Type | Current Rating (A) | Full Stroke (mm) | Initial Height (mm) | Working Height (mm) | Body Height (mm) |
|---|---|---|---|---|---|
| Compact High Current Pogo Pin | 2~5A | 0.80~1.50 | 3.00~6.50 | 2.20~5.50 | 2.80~5.50 |
| Standard High Current Pogo Pin | 5~10A | 1.50~2.00 | 4.50~9.00 | 3.20~7.80 | 4.00~7.00 |
| Large Barrel High Current Pogo Pin | 10~15A | 2.00~2.50 | 6.00~12.00 | 4.20~10.20 | 5.50~9.00 |
| Rolling Ball High Current Pogo Pin | 10~20A | 2.00~3.00 | 6.50~13.50 | 4.80~11.50 | 6.00~10.00 |
| Heavy Duty High Current Pogo Pin | 15~30A | 2.50~3.50 | 8.00~16.00 | 5.80~13.50 | 7.00~12.00 |
| Battery Contact High Current Pogo Pin | 20~40A | 3.00~4.00 | 9.00~18.00 | 6.50~15.50 | 8.00~14.00 |
| Ultra High Current Pogo Pin | 30~60A | 3.50~5.00 | 10.50~22.00 | 7.50~19.00 | 9.00~16.00 |
High Current Spring Loaded Pin Performance
High Current Pogo Pin Technical Parameters
Pexon custom pogo pins are carefully crafted using only the finest materials.
Our production team offers superior craftsmanship with over 10 years of experience working with custom high current pogo pins / high current pogo pin connectors.
| Items | Details |
|---|---|
| Material | Plunger: Lead Free Copper Alloy |
| Body: Lead Free Copper Alloy | |
| Spring: Stainless Steel | |
| Solid Pin: Lead Free Copper Alloy | |
| Main Technical Parameters | Standard state: |
| Operating temperature: -40~+120°C (Standard) | |
| Operating humidity: 20-85% RH | |
| Storage temperature: -10~+50°C | |
| Storage humidity: 20-85% RH | |
| Rating voltage: 36V AC/DC (Standard) | |
| Rating current: 2A/Pin Continuous (Standard) | |
| Contact resistance: 30 mΩ Max. (Standard) | |
| Withstanding voltage: 250V AC, 1 Minute | |
| Insulation resistance: 500 MΩ Min. | |
| Durability: 10,000 Cycles (Standard) | |
| Working Spring Force: 40~120 gf (Standard) | |
| Electroplating | Plunger: Ni Plating 1.4μm, Gold Plating 0.30μm |
| Body: Ni Plating 1.4μm, Gold Plating 0.10μm | |
| Solid Pin: Ni Plating 1.4μm, Gold Plating 0.10μm | |
| Contact Type | Vertical Contact Type |
| Installation Method | SMT automatic placement machine + Reflow soldering |
| Plugin machine + Wave soldering | |
| Environmental Protection Standard | Comply with EU RoHS and Pexon standards |
types of test probes
Selection Guide of Test Probes
Select spring pin connector based on travel length, spring force, contact material, and plating to achieve optimal performance, reliability, and durability.
Fully customizable to meet any electrical, mechanical, or environmental requirements.
| Part No. | Current Rating | Rated Resistance | Full Stroke | Rated Stroke | Spring Force | Bandwidth | Mechanical Life Exceeds | Download Drawings |
|---|---|---|---|---|---|---|---|---|
| DP020-xx-57-0.3GG(SS) | 0.5A | 100 milliohm max | 1.10mm | 0.65mm | 8±2gf@load 0.65mm(0.3oz) | [email protected] | 100000 cycles |
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| DP021-xx-57-0.3GG(SS) | 0.5A | 100 milliohm max | 1.10mm | 0.65mm | 8±2gf@load 0.65mm(0.3oz) | [email protected] | 100000 cycles |
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| DP026-xx-57-0.5GG(SS) | 0.5A | 100 milliohm max | 1.10mm | 0.65mm | 14±3gf@load 0.65mm(0.5oz) | [email protected] | 100000 cycles |
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| DP028-xx-57-0.6GG(SS) | 1A | 100 milliohm max | 1.10mm | 0.7mm | 20±5gf@load 0.7mm(0.6oz) | [email protected] | 100000 cycles |
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| DP030-xx-57-0.35GG(SS) | 1A | 100 milliohm max | 1.10mm | 0.65mm | 10±5gf@load 0.65mm(0.35oz) | [email protected] | 100000 cycles |
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| DP031-xx-57-0.7GG(SS) | 1A | 100 milliohm max | 1.10mm | 0.65mm | 20±5gf@load 0.65mm(0.7oz) | [email protected] | 100000 cycles |
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| DP035-xx-57-0.85GG(BB) | 1A | 100 milliohm max | 1.10mm | 0.65mm | 24±5gf@load 0.65mm(0.85oz) | [email protected] | 100000 cycles |
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| DP035-xx-86-0.8GG(BB) | 1A | 100 milliohm max | 1.30mm | 0.8mm | 23±5gf@load 0.80mm(0.8oz) | [email protected] | 100000 cycles |
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| DP038-xx-57-0.4GG(BB) | 1A | 100 milliohm max | 1.10mm | 0.65mm | 11±3gf@load 0.65mm(0.4oz) | [email protected] | 100000 cycles |
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| DP038-xx-57-1.1GG(BB) | 1A | 100 milliohm max | 1.10mm | 0.65mm | 30±6gf@load 0.65mm(1.1oz) | [email protected] | 100000 cycles |
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| DP038-xx-63-0.85GG(BB) | 1A | 100 milliohm max | 1.10mm | 0.80mm | 24±5gf@load 0.80mm(0.85oz) | [email protected] | 100000 cycles |
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| DP051-xx-57-0.7GG(BB) | 1A | 100 milliohm max | 1.10mm | 0.65mm | 20±5gf@load 0.65mm(0.7oz) | [email protected] | 100000 cycles |
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| DP051-xx-61-1.2GG(BB) | 1A | 100 milliohm max | 1.30mm | 0.95mm | 34±8gf@load 0.95mm(1.2oz) | [email protected] | 100000 cycles |
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| DP051-xx-63-0.7GG(BB) | 1A | 100 milliohm max | 1.50mm | 1.00mm | 20±4gf@load 1.00mm(0.7oz) | [email protected] | 100000 cycles |
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| DP057-xx-31-1.1GG(BB) | 2A | 100 milliohm max | 0.60mm | 0.48mm | 30±6gf@load 0.48mm(1.1oz) | [email protected] | 100000 cycles |
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| DP058-xx-57-1.1GG(BB) | 2A | 100 milliohm max | 1.10mm | 0.65mm | 30±5gf@load 0.65mm(1.1oz) | [email protected] | 100000 cycles |
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| DP058-xx-63-1.1GG(BB) | 2A | 100 milliohm max | 1.30mm | 0.85mm | 30±6gf@load 0.85mm(1.1oz) | [email protected] | 100000 cycles |
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| DP078-xx-57-0.9GG(BB) | 2A | 100 milliohm max | 1.50mm | 0.80mm | 26±5gf@load 0.80mm(0.9oz) | [email protected] | 100000 cycles |
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| DP078-xx-63-1.2GG(BB) | 2A | 100 milliohm max | 1.50mm | 0.80mm | 35±7gf@load 0.80mm(1.2oz) | [email protected] | 100000 cycles |
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| DP085-xx-57-1.1GG(BB) | 2A | 50 milliohm max | 1.10mm | 0.65mm | 30±6gf@load 0.65mm(1.1oz) | [email protected] | 100000 cycles |
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| DP100-xx-131-3.5GG(BB) | 2A | 50 milliohm max | 3.10mm | 2.00mm | 100±30gf@load 2.00mm(3.5oz) | [email protected] | 100000 cycles |
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| DQ031-xx-33-0.9GG(BB) | 1A | 100 milliohm max | 0.55mm | 0.45mm | 26±5gf@load 0.45mm(0.9oz) | [email protected] | 100000 cycles |
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| DE058-xx-88-1.2GG(BB) | 2A | 100 milliohm max | 1.20mm | 0.80mm | 35±7gf@load 0.80mm(1.2oz) | [email protected] | 100000 cycles |
|
| DE078-xx-88-1.2GG(BB) | 2A | 100 milliohm max | 1.50mm | 1.00mm | 35±7gf@load 1.00mm(1.2oz) | [email protected] | 100000 cycles |
|
| HDE065-xx-113-1.6GG(BB) | 2A | 100 milliohm max | 1.70mm | 1.10mm | 45±9gf@load 1.10mm(1.6oz) | [email protected] | 100000 cycles |
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| HDE052-xx-63-0.7GG(BB) | 1A | 100 milliohm max | 1.50mm | 1.00mm | 20±4gf@load 1.00mm(0.7oz) | [email protected] | 100000 cycles |
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| Part No. | Current Rating | Contact Resistance |
Spring Force at Stroke (The brackets are customized) |
Download Drawings |
|---|---|---|---|---|
| P020 | 0.3A | 220 milliohm max(Rated Resistance) |
1.50mm(Full Stroke) 20g(Spring Force at Full Stroke) |
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| R020 |
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| P026 | 0.3A | 220 milliohm max(Rated Resistance) |
1.50mm(Full Stroke) 20g(Spring Force at Full Stroke) |
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| R026 |
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| P030 | 1A | 100 milliohm max(Rated Resistance) |
1.50mm(Full Stroke) 20g(Spring Force at Full Stroke) |
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| R030 |
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| P035 | 1A | 100 milliohm max(Rated Resistance) |
1.50mm(Full Stroke) 40g(Spring Force at Full Stroke) |
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| R035 |
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| P038 | 1A | 50 milliohm max |
1.50/2.0mm(Full Stroke) 40g(Spring Force at Full Stroke) |
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| R038 |
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| P048 | 2A | 50 milliohm | (20g)40g |
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| R048 |
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| P058 | 2A | 50 milliohm max | (20g)70g |
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| R058 |
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| P50 | 3A | 50 milliohm max | (20g)(40g)75g(120g) |
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| R50 |
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| P02 | 3A | 50 milliohm max | 90g(120g) |
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| R02 |
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| PL50 | 3A | 50 milliohm max | 100g |
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| RL50 |
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| P75 | 3A | 50 milliohm max | (60g)100g(180g)(220g) |
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| R75 |
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| PM75 | 3A | 50 milliohm max | (60g)(100g)120g |
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| RM75 |
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| PL75 | 3A | 50 milliohm max | (60g)(90g)120g(200g)(250g) |
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| RL75 |
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| P11 | 3A | 50 milliohm max | (80g)150g |
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| R11 |
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| P100 | 3A | 50 milliohm max | (40g)(90g)(120g)180g(250g)(280g)(350g) |
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| R100 |
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| P125 | 5A | 50 milliohm max | (70g)180g(250g)(350g) |
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| R125 |
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| P156 | 5A | 50 milliohm max | (50g)(200g)250g(280g)(380g) |
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| R156 |
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| G1353 | 3A | 50 milliohm max | 180g(280g) |
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| R1353-4W |
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| GL1353 | 3A | 50 milliohm max | 250g |
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| GL1353-W |
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| S1353 | 3A | 50 milliohm max | (180g)340g |
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| RS1353-W |
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| 1353L | 3A | 50 milliohm max | 380g |
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| RL1353-W |
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| P160 | 3A | 50 milliohm max | (40g)(60g)(100g)180g(280g)(340g) |
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| R160 |
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| Part No. | Current Rating | Contact Resistance | Spring Force at Stroke | Download Drawings |
|---|---|---|---|---|
| SP125 | 5A | 50 milliohm | 1.8N(180gf),3.5N(350gf) |
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| SP156 | 5A | 50 milliohm | 2.5N(250gf),3.5N(350gf) |
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| SP169 | 5A | 50 milliohm | 6N(600gf) |
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| SP189 | 5A | 50 milliohm | 6N(600gf) |
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| SP040 | 2A | 30 milliohm max | 80gf |
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| SP050 | 3A | 30 milliohm max | 2N(200gf),3N(300gf) |
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| R050 |
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| SP075 | 3A | 30 milliohm max | 2N(200gf),3N(300gf) |
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| R075 |
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| SP135 | 5A | 30 milliohm max | 2N(200gf),3N(300gf) |
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| SP100 | 5A | 30 milliohm max | 2N(200gf),3N(300gf) |
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| R100 |
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| SQ050 | 3A | 30 milliohm max | 2N(200gf),3N(300gf) |
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| SQ075 | 3A | 30 milliohm max | 2N(200gf),3N(300gf) |
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| SQ100 | 5A | 30 milliohm max | 2N(200gf),3N(300gf) |
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| SP-ICT058-X-2.4 | 2A | 50 milliohm max | 70gf@load 2.60mm(2.4oz) |
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| SP-ICT076-XX-3.5-GG | 3A | 50 milliohm max | 95gf@load 4.30mm(3.5oz) |
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| SP-078-X-3.9 | 3A | 50 milliohm max | 110gf@load 2.60mm(3.9oz) |
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| Part No. | Current Rating | Rated Resistance | Full Stroke | Rated Stroke | Spring Force | Download Drawings |
|---|---|---|---|---|---|---|
| CH137-x-2.5G(B) | 3A | 100 milliohm max | 7.1mm | 3.0mm | 70±20gf@load 3.0mm |
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| CH137(20)-x-3.5G(B) | 3A | 100 milliohm max | 4.2mm | 2.8mm | 100±30gf@load 2.8mm |
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| CH165-x-4G(B) | 3A | 100 milliohm max | 5.3mm | 3.5mm | 113±35gf@load 3.5mm |
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| CH265-x-4G(B) | 3A | 100 milliohm max | 5.5mm | 3.5mm | 113±35gf@load 3.5mm |
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Switch Probe (Normally Open) |
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Switch Probe KG-250G (Normally Closed) |
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| Part No. | Hole Size | Current Rating | Rated Resistance | Spring Force(The brackets are customized) | Download Drawings |
|---|---|---|---|---|---|
| PH-101 | 2.0mm | 200g Stroke |
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| PH-10 | 2.0mm | 200g Stroke |
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| PH-15 | 3.0mm | 270g(100g) Stroke |
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| PH-18 | 3.5mm | 200g(300g)(600g) Stroke |
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| PH-1,2,3,4,5,6 | 3.5-10.5mm | 100g-250g Stroke |
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| PH-1020 | 1.33mm(or1.5mm) | 150g(220g)(350g) full |
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| PH-1021 | 1.05mm(or1.35mm) | (60g)150g full |
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| PH-1030 | 0.85mm(or1.10mm) | 100g(150g) full |
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| PH-1034 | 0.5mm(or0.7mm) | 120g(240g) full |
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| PH-1040 | 2.0mm(or2.5mm) | 120g,240g,280g full |
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| PH-1041 | 1.25mm(or1.65mm) | 120g,240g,280g full |
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| PH-1050 | 2.9mm(or3.3mm) | (200g)250g(350g)(400g) full |
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| PH-1051 | 2.4mm(or2.8mm) | (200g)250g(350g)(400g) full |
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| PH-1052 | 1.65mm(or2.05mm) | (200g)250g(350g)(400g) full |
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| Current and voltage 290x3600 | 15A | <30 milliohm |
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| R50Current and voltage 420x4450 | 15A | <30 milliohm |
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| High current probe JTS120 | 24A | <10 milliohm | 230g(300g) work |
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| High current probe JTS150 | 50A | <8 milliohm | 300g work |
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| High current probe JTS355 | 12A | <15 milliohm | (200g)480g work |
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| High current probe JTS420 | 15A | <12 milliohm | 650g(1000g)(1800g) work |
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| Capacitor Polarity Probe PH18 | 3.45mm | 530g outer |
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| Capacitor Polarity Probe M4 X 6780 | 4.0mm | 350g outer |
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| High-Frequency Probe 10445 | 3A |
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| High-Frequency Probe JT-CT | 3A | 50 milliohm | 300g |
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| High-Frequency Probe JTK-50L-Q |
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| High-Frequency Probe JTK-50L |
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| Directional probe 265X2980-H | 8-10A | 50 milliohm |
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| Directional probe 265X3080-T | 8-10A | 50 milliohm |
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Upload Your CAD File
To begin, provide your contact details and upload the CAD file or detailed product requirements of your design. This allows us to create a detailed 3D model of the part or prototype you're looking to produce.
Receive a Quote & Design Review
Within 12 hours, we’ll send you a detailed quote along with Design for Manufacturability (DFM) feedback. This ensures the feasibility of your project and gives you a clear idea of the costs involved.
Confirm Your Order & Begin Production
Once you approve the quote and design, we’ll proceed with the production of your custom high current pogo pins.
Shipping & Delivery
Your project enters our manufacturing queue the morning after we receive your approval. On average, custom orders ship within 10-15 business days. In stock products and samples ship within 48 hours.
Just 4 Steps
Custom High Current Pogo Pin Quotation Process
From detailed consultation to final delivery, we make custom pogo pin orders simple and easy. We pride ourselves on providing exceptional customer service by anticipating your needs, offering customized solutions and on time delivery.
High Current Spring Loaded Pins Electroplating
High Current Pogo Pin Surface Treatment
Various surface treatment methods to meet your needs
Electroplated Gold - Golden Yellow
Electroplated Nickel - Silver White
Before Electroplating - Brass Color
Packaging Options for High Current Pogopin
Pogo Pin Packaging Method
Enabling you to move seamlessly from receiving to production without compromise.
Pogo Pins Vacuum Carrier Tape Packaging
Pogo Pin Connector Vacuum Carrier Tape Packaging
High Current Contact Pin Customization Process
From Design to Quality Control
Every Step Tailored to Perfection
Pexon high current pogo pin customization process ensures precision, quality, and efficiency at every stage. From innovative design and advanced production to rigorous quality control, we transform your ideas into high performance solutions. Serving diverse industries, we specialize in creating prototypes and full scale production, turning your vision into reality with unmatched expertise and attention to detail.
Professional Equipment For High Current Springloaded Pin
The Equipment Behind Custom Pogo Pins
Our professional equipment provides complete solutions for pogo pin customization, ensuring high precision, efficiency, and cost effectiveness.
From design to production, we meet strict quality standards, addressing complex shapes and performance needs.
automatic lathe
High speed auto feeding turning
milling machine
Complex precision machining
stamping press
High accuracy & rigidity
spring coiling machine
Free height & wire diameter precision
electroplating machine
Uniform, clean
coordinate measuring machine
Dimensional & tolerance verification
Pexon Pogo Pin
Related Pogo Pin
From initial prototypes to large scale production, we ensure top quality results and help you achieve your manufacturing goals.
Pogo Pin Professional Guide
Pogo Pin Knowledge
High Current Pogo Pin FAQ
Pexon high performance pogo pins, ideal for functional tests or end use applications. Explore our FAQs to discover more about our pogo pin solutions and related technical support.
We need drawings or key specs: size, stroke, force, current, plating, and usage.
Standard parts: 3–7 days. Custom parts: 2–4 weeks depending on complexity.
Yes, sample testing can be provided before mass production.
Yes, we support full customization based on size, force, plating, and structure.
Yes. Our engineering team can provide suggestions on structure, plating, tolerance, and manufacturability.
Yes. Material certificates and quality inspection reports can be provided if required.
Yes. Key dimensions can be checked according to your drawing requirements.
We offer standard packaging and custom packaging based on customer requirements.
Yes. Customized labels and packaging identification can be arranged.
Yes. We can sign an NDA to protect customer drawings and project information.