Wexmar provides custom connector machining for electrical, RF, fluid and instrumentation connectors. Our Canastota, New York shop produces CNC machined connector shells, coupling nuts, contact pins, sockets and housings on Swiss-type machines, CNC lathes and horizontal machining centers. We work build-to-print for OEMs and government programs, and a human estimator reviews every quote.
What connectors do and who buys them
A machined connector joins two conductors or two fluid lines and must do it repeatably, often thousands of mating cycles. Dimensions on the mating interface set contact pressure, sealing and alignment. Our connector customers typically include:
- Electrical and connector manufacturers that outsource shells, contacts and coupling hardware
- Instrumentation and sensor makers needing small threaded housings
- Medical hardware builders with small precision fittings
- Defense, government and aerospace hardware programs with build-to-print connector components
How our custom connector machining works
Swiss machining for pins, sockets and small shells
Contacts, pins, sockets and shells up to 32 mm diameter run on our four Maier MLK-32 Swiss-type machines with FMB bar feeders. Swiss turning holds long, slender contacts straight, drills deep socket bores on center and cuts cross slots and crimp holes in the same cycle. These machines run lights-out, which suits the high piece counts connector programs usually need. See Swiss machining.
CNC lathes for larger shells and coupling nuts
Larger receptacle shells, jam nuts and coupling rings run on our Mazak and Doosan lathes. Live tooling cuts keyways, flats and cross holes, and Y-axis milling handles polarization keys and off-center features without re-fixturing.
Horizontal milling for housings
Rectangular connector housings, flanged receptacles and multi-port blocks are milled on our Mazak horizontal machining centers with 4th-axis indexing, so all faces are cut from a common datum.
Typical connector materials
- Brass and leaded brass for shells, coupling nuts and contacts
- Copper and bronze alloys for current-carrying contacts
- 303 and 316 stainless for harsh environment and sealed connectors
- 6061 aluminum for lightweight shells and housings
- Titanium and engineered plastics for weight, isolation or chemistry needs
Critical features and how we hold them
- Contact diameter and socket bore: held on Swiss machines where the guide bushing controls deflection.
- Coupling threads: single-point cut or thread milled and gaged to class 2A/2B or 3A/3B.
- Mating face position: keys, pin holes and polarization features are cut in one setup so their true position relates directly to the thread and bore datums.
- Burr control: socket entries and crimp holes are deburred in-cycle where possible so parts are ready for plating.
Typical connector tolerances and finishes
| Feature | Typical tolerance | Tighter on request |
|---|---|---|
| Pin or contact diameter | +/-0.0005 in | +/-0.0002 in |
| Socket bore | +/-0.0005 in | +/-0.0003 in |
| Coupling thread | Class 2A / 2B | Class 3A / 3B |
| Key or pin true position | 0.005 in | 0.002 in |
| Shell concentricity | 0.002 in TIR | 0.001 in TIR |
| Surface finish before plating | 63 Ra | 32 Ra |
Values are typical and depend on size, material and length-to-diameter ratio. We confirm what we will hold on each quote.
Secondary operations
Gold, silver, nickel and tin plating, anodizing, passivation and heat treat of spring contacts are completed through qualified outside processors. We account for plating build-up when machining critical diameters and inspect parts on return.
Design notes for machined connector parts
A few drawing details have an outsized effect on connector cost. Deep, small-diameter socket bores are easier to hold when the drill depth stays within about ten diameters, or when a larger counterbore relieves the entry. Crimp barrels and solder cups machine cleaner when wall thickness is uniform. Coupling threads that end in a relief groove, rather than running into a shoulder, gage more reliably. Where plating is specified, calling out dimensions as after-plate or before-plate removes guesswork. We review these points with you at the quote stage and flag anything that drives cost or risk.
Quantity patterns
Connector parts often start with a few hundred qualification pieces and move to blanket orders of thousands per release. Lights-out Swiss capacity and a second shift keep per-piece cost down on repeat runs.
Inspection
Critical diameters, thread class and position are verified with thread gages, our Brown and Sharpe CMMs and the Mitsubishi optical comparator. FAI in AS9102 format, CMM reports, material certs and heat-lot traceability are available. See inspection and quality.
Getting a quote
Send drawings, material, plating callouts and annual volume. You can upload a drawing for an instant estimate, and an estimator will confirm price and lead time. Call (315) 400-2654 to discuss a connector program.