Electrical connectors

Name: Intechatandart LLC
Address: Ulyanova Street, Building 4/1, Premises 4, Room 2, Bryansk, Bryansk Region, 241035, RU
Telephone: +7 (910) 734-80-04

Connector R&D with a full package of design documentation (KD), technical specifications (TU) and process documentation (TD). Import substitution of foreign analogues, serial production of our own connector series.

Send a drawing

KD · TU · TD

full package

4 mo.

typical cycle

> 5,000

pcs per series

Anatomy

Inside the RS-32 connector

Key components: a bayonet-locking housing, dielectric insulator, gold-plated contact set and an IP67 seal.

CONNECTOR · CROSS-SECTIONCONNECTORS / 01

01 / Scope

What the service includes

01 / 04

Import substitution

Replacement of foreign analogues from a sample.

02 / 04

R&D for an analogue

Development work with a full documentation package.

03 / 04

Serial production

Our own connector series in serial production.

04 / 04

Support

Modifications and change management per plant regulations.

02 / Electrical and mechanical characteristics

Series and test parameters

Target values verified during PMI testing. Specific values per series — in the product's technical specifications (TU).

Parameter

Value

Ra · precision

Contact resistance
Baseline requirement
≤ 5 mΩ
GOST 23784
Baseline requirement
Insulation resistance
At normal conditions
≥ 1,000 MΩ
GOST 14312
At normal conditions
Dielectric strength
Between contacts and housing
1,000 V / 1 min
GOST 14312
Between contacts and housing
Operating voltage
Depends on contact pitch
up to 500 V DC
Per TU
Depends on contact pitch
Operating current per contact
Depends on ⌀ and material
5 A / ⌀ 1.0 mm
GOST 23784
Depends on ⌀ and material
Mating cycle life
With inspection after the life test
≥ 500 cycles
GOST 27.301
With inspection after the life test
Mating / unmating force
Depends on contact count
≤ 40 N
Per TU
Depends on contact count
Vibration resistance
Aviation and special equipment
up to 20 g · 10–2,000 Hz
GOST 16962
Aviation and special equipment
Shock
Aviation and special equipment
up to 150 g, 1 ms
GOST 16962
Aviation and special equipment
Operating climate
Standard version
-60…+85 °C
GOST 15150
Standard version
Extended climate
For special equipment
-65…+125 °C
GOST 15150
For special equipment
IP rating
By version
IP54 / IP67 / IP68
GOST 14254
By version

The test program and procedures are agreed at the R&D stage. Test scope — standard per TU or extended per the customer's request.

03 / Materials

Materials and tolerance by size

Series

Design

Contacts

IP / climate

RS-32 (import substitution)

Cylindrical, bayonet

32, ⌀1.0 mm

IP67 · -60…+85 °C

Rectangular DSUB analogue

Rectangular, screw-lock

9 / 15 / 25

IP54 · -55…+85 °C

Aviation MIL-DTL analogue

Cylindrical, threaded

up to 128

IP68 · -65…+125 °C

High-current

Cylindrical, latch

1–4, ⌀5 mm

IP67 · up to 100 A / contact

PCB-mount

Rectangular, straight/angle

up to 200, 2.54 pitch

IP20 · -40…+85 °C

04 / Connector machinery

The equipment we work on

Machinery for manufacturing contact groups, housings and connector tooling.

5-axis machining centre01 / 05

5-axis machining centre

Mazak VARIAXIS i-700

Complex geometries and undercuts in a single setup — no refixturing.

Work envelope: 700 × 700 × 500 mm
Spindle: up to 12,000 rpm
Repeatability: ±0.003 mm
Tool magazine: 30 tools

Wire EDM02 / 05

Wire EDM

Sodick AQ535L

Contour cutting of complex profiles and internal contours with IT7 tolerance.

Work envelope: 500 × 350 × 250 mm
Thickness: up to 250 mm
Wire: ⌀ 0.1–0.3 mm
Accuracy: ±0.003 mm

Swiss-type lathe03 / 05

Swiss-type lathe

Tsugami B0206-V

Serial turning of contacts and small precision parts from bar stock in one setup.

Bar ⌀: up to 20 mm
Spindles: 10,000 / 12,000 rpm
Tools: 27 stations
Control: FANUC 0i-TF Plus

Surface grinder04 / 05

Surface grinder

Okamoto ACC-1224ST

Plates, bases and guides — after heat treatment.

Work table: 600 × 300 mm
Accuracy: ±0.002 mm
Surface finish: Ra 0.2 µm
Magnetic table: —

Polishing station05 / 05

Polishing station

Manual + diamond paste

Surface finishing to a mirror finish and sealing joints.

Surface finish: Ra down to 0.02 µm
Inspection: SJ-410 profilometer
For steels: S136, 2316, 718H
Application: Optical, medical plastics

Equipment class; the exact lineup and serial numbers — on request under NDA.

05 / Electrical testing

How we test connectors

Contact resistance, insulation, dielectric strength, mating cycle life. Accredited laboratory — at a partner.

Primary instrument

Contact resistance test setup

MIKO-9 micro-ohmmeter

Range: 10 µΩ – 200 Ω
Accuracy: 0.1%
Standard: GOST 23784
Application: Every batch

Insulation test setup

GW Instek GPT-9803

Voltage: up to 5 kV AC / 6 kV DC
Leakage current: 0.1 mA – 100 mA
Test modes: GOST 14312
Application: Hipot test

Life test setup

Mating cycle test rig

Cycles: up to 10,000
Speed: up to 30 cycles/min
Inspection: resistance after the life test

Climatic chamber (partner)

ESPEC SH-262

Temperature: -70…+180 °C
Humidity: 20…98 %
Standards: GOST 15150 / IEC 60068

06 / R&D checklist

8 rules to start connector R&D

What is needed to start import substitution work. The more detail up front — the fewer approval iterations.

Rule 01 / 08

Reference sample

At least 2 working pcs + 1 for destructive analysis

For reverse engineering and parameter verification.

Rule 02 / 08

Electrical parameters

Operating U, I, contact R, insulation R, mating cycle life

If parameters are unavailable — we take them from the analogue and agree.

Rule 03 / 08

Application and environment

Climate, IP, vibration / shock, chemical environment

Defines the choice of materials and the test program.

Rule 04 / 08

Mating dimensions

Contact pitch, contact ⌀, housing envelope, mounting

We hold these dimensions within ±0.05 mm for compatibility.

Rule 05 / 08

Contact plating

Au — premium · Ag — standard · Sn — volume · Ni — underlayer

Affects life, contact resistance and price.

Rule 06 / 08

Accuracy class and tolerances

Contacts ±0.005 mm · housing ±0.05 mm · h7/H7 fits

Conformance to the foreign analogue is confirmed by measurement.

Rule 07 / 08

Volumes and production run

Pilot batch — 50 pcs · series — from 500 pcs per quarter

Series size drives the process choice (moulding vs stamping).

Rule 08 / 08

Marking and certification

Marking per TU · certification in the customer's system / GOST R

Certification is carried out in accredited laboratories.

07 / R&D documentation

What to send to start R&D

To start connector R&D, a reference sample plus a specification is enough. Additional data speeds up approvals.

Minimum drawing content

DRAWING / EXAMPLE

01Reference sample (physical) for measurement
02Operating electrical parameters (U, I)
03Climatic version (T, humidity)
04IP and vibration resistance requirements
05Mating dimensions
06Contact plating and housing material
07Batch marking and packaging
08Volumes (pilot batch + series)

3D formats

·STEP / STP (if available)
·IGES / IGS
·X_T (Parasolid)
·SLDPRT / PRT
·Reference sample (physical)
·Electrical schematic (E3)

2D drawings

·DWG / DXF (if design docs for the analogue exist)
·PDF datasheet of the foreign analogue
·Sketch with mating dimensions

08 / Plating and finishing

Contacts and housing: platings

Contacts — electroplating chosen by life and cost. Housings — finish for the operating environment.

Through trusted partners

Electroplating, heat treatment and complex coatings go to specialised shops under a defined procedure.

Contact silver plating (Ag)
GOST 9.301-86
3–9 µm · standard
Contact gold plating (Au)
ASTM B488
0.5–3 µm over Ni underlayer
Contact tin plating (Sn)
GOST 9.301-86
5–15 µm · solderable
Nickel underlayer
GOST 9.301-86
2–6 µm under Au / Ag
Housing chromating (Al)
GOST 9.301-86
Cr3+ / Cr6+ as required
Housing anodising
GOST 9.301-86
8–25 µm, black / colour

09 / Case studies

From real work in this area

A few case studies that show what we actually do. An extended pack with reports and process video is available under NDA.

All case studies

Connector RS-32 — replacement of a foreign analogue

Connectors01 / 01

2025

Radio electronics · 2025

Connector RS-32 — replacement of a foreign analogue

R&D with a full set of design and process documentation. Serial production launched for an instrumentation plant.

Material: brass LS59-1
Tolerance: ±0.01 mm
Volume: 5,000 pcs
Lead time: 4 months

Open case study

10 / Documentation

What we deliver

A complete documentation package, ready for certification in the customer's system or under GOST R.

Design documentation (full set)Technical specifications (TU)Process documentationTest reports (electrical, climatic, mechanical)Material certificate (brass / dielectric)Test program and procedures (PMI)

11 / FAQ

Frequently asked questions

01How long does a full R&D cycle take?

The typical cycle is 3–4 months from receiving the reference sample to series launch. With an extended test program — up to 6 months.

02What documentation do you prepare?

The full package: design documentation, technical specifications, process documentation, test program, test reports (climatic, mechanical, electrical). Delivered electronically and as signed hard copies.

03Can you confirm interchangeability?

Yes — testing of mating dimensions, contact resistance and mating cycles. The report is attached to the batch.

04What contact groups are available?

⌀ 1.0 / 1.5 / 2.0 / 3.0 / 5.0 mm. Material — brass LS59-1, bronze BrB2 with Au / Ag / Sn / Ni electroplating.

05Certification for aviation / special equipment?

We prepare documentation for the customer's certification system. Testing in accredited laboratories — via partners.

Inquiry

Send a drawing —
we'll quote within 24 hours

Fill in the form or contact us directly — any channel works.