Custom EV Charging Pins | Type 2, CCS, NACS — Made to Print

Direct answer: VOLCRIX manufactures custom EV charging pins for Type 2 (IEC 62196-2), CCS Combo 1/2 (IEC 62196-3 / UL 2251), and NACS (SAE J3400) connectors. Every pin is CNC Swiss turned from C18150, C11000, or tellurium copper per ASTM B301, held to ±0.01 mm OD with full material traceability. We ship prototypes in 7–15 days and production lots in 3–4 weeks. Bar turned components for electronic connectors is the technology we have been running since 1991 on 60 Star Swiss turning machines. Send your STEP file and 2D drawing to our quoting form, or message us on WhatsApp at +86 188 6828 5255.

Common Applications for EV Charging Pins

EV charging pins are high-current bar turned components for electronic connectors in the most demanding e-mobility applications. The four programs we run most often:

• Type 2 AC charging pins (IEC 62196-2). L1, L2, L3, N, PE power contacts at 16 A / 32 A single-phase and three-phase up to 480 V AC. CP and PP signal contacts (low-current, precision-machined). Typically turned from C11000 (ETP copper, 101% IACS conductivity) with silver plating per ASTM B700.
• CCS Combo 1 and Combo 2 DC fast-charge pins (IEC 62196-3 / UL 2251). DC power contacts rated up to 500 A continuous and 1000 V DC. These bar turned components for electronic connectors use thicker cross-sections (6 mm to 12 mm OD), C18150 (CuCrZr) for higher current density, and a precision-cooling channel machined into the pin body. Surface finish: silver plating 3–5 µm over nickel 1–2 µm.
• NACS (SAE J3400 / Tesla) North American standard pins. Power and signal contacts for the NACS connector deployed across North America. We turn these pins from C18150 rod with ±0.01 mm OD tolerance and 0.4 µm Ra surface finish. UL 2251 certified process with batch-level Hi-Pot testing at 2500 V AC for 60 seconds.
• Proprietary and OEM-defined EV charging pin designs. Custom geometries for OEM-specific connectors, non-standard pin lengths, integrated spring fingers, and multi-stage turned profiles. We routinely handle 3 to 5 turned diameters in a single pin with no secondary machining needed.

Manufacturing Support from VOLCRIX for EV Charging Pins

When an EV charging pin drawing lands on our engineering desk, we look at three things first: copper grade, plating spec, and current rating. These three decide which Star machine, tooling, and cycle time apply. Here is what we deliver on every program:

• Material selection across pure copper and copper alloys. C11000 (ETP copper, 101% IACS) for AC charging pins; C18150 (CuCrZr, 80% IACS, higher strength) for DC fast-charge; tellurium copper C14500 (90% IACS, better machinability) for high-volume signal pins; brass C3604 for low-current signal contacts. Every batch ships with mill cert per EN 10204 3.1 and incoming spectrometer check on Bruker Q4 Tasman.
• 60 Star Swiss turning machines, 1991 vintage onwards. We run Star SR-20, SR-20R, SR-38, and SB-20R for bar turned components up to 38 mm OD. For pins above 38 mm OD we use Doosan and Mazak turning centers with bar feeders. Main spindle accuracy ±0.005 mm; sub-spindle accuracy ±0.01 mm for back-side operations.
• In-process plating and post-plating options. Silver (3–5 µm per ASTM B700) for low contact resistance at high current; tin (5–8 µm per ASTM B545) for solderable terminations; nickel (1–3 µm per ASTM B689) as a diffusion barrier under silver or tin; gold (0.5–1.0 µm over nickel) for signal contacts requiring stable low-level resistance. We source plating through Wenzhou-qualified partners and verify thickness on XRF (Fischer XDLM).
• Hi-Pot, continuity, and dimensional inspection. Every lot is Hi-Pot tested at 2500 V AC for 60 s (per UL 2251), 100% continuity-checked, and verified on Zeiss Contura CMM with Cpk ≥ 1.33 on critical pin OD and length features. FAI per AS9102 with PPAP support for automotive OEM programs.
• Crimp-and-cable sub-assembly on request. For turnkey charging pin assemblies, we crimp the pin to the cable (35 mm² to 95 mm² cross-section) using TE Connectivity or Schneider tooling, apply heatshrink, and label per customer spec. We have built 50,000+ pin-cable sub-assemblies in the last 12 months for European and US EV charging OEMs.

EV Charging Pin Buyer Checklist

Four items that determine whether your bar turned components program runs smoothly:

• Specify copper grade and temper, not just “copper”. C11000, C18150, and C14500 all behave differently under high current and at elevated temperature. The wrong copper can melt at the rated current density. Confirm the alloy on the drawing; if you only have a conductivity target, we will recommend the closest fit.
• Mark plating thickness and plating sequence. Silver over nickel is the standard for high-current DC pins; gold over nickel for low-current signal pins. The plating stack determines both contact resistance and corrosion performance, and the spec should be explicit (e.g. “Ag 3 µm min over Ni 1.5 µm min per ASTM B700”).
• Define the current rating and temperature class. A 32 A AC pin and a 500 A DC pin are not the same part. Pin OD, wall thickness, and copper grade change with current rating. UL 2251 and IEC 62196-3 spec the testing per class.
• Confirm Hi-Pot, partial discharge, and salt spray testing scope. Standard scope includes Hi-Pot at 2500 V AC for 60 s and dimensional FAI. Optional scope includes partial discharge testing, salt spray per ASTM B117 (96 h to 500 h), and thermal cycling (-40 °C to +125 °C per IEC 60068-2-14). Flag the testing scope on the RFQ so the quote reflects it.

Authority Summary

Related Custom Manufacturing Services

• Aviation Connector Pins | Custom Machined Contacts — aerospace-grade MIL-DTL-38999 and GX series contact pins
• Custom Electronic Contact Pins — signal-level and power contact pins for industrial connectors
• Precision Swiss Turning for EV Charging Contact Pins — process overview and alloy selection guide

Frequently Asked Questions

What copper grade should I use for DC fast-charge EV charging pins?

C18150 (CuCrZr, 80% IACS) is the standard for DC fast-charge pins up to 500 A. C11000 (ETP, 101% IACS) is acceptable for AC charging pins up to 32 A. Tellurium copper C14500 (90% IACS) is used where machinability matters more than conductivity, typically for signal pins. Avoid brass for high-current pins — brass loses strength at the operating temperature of fast-charge connectors.

What tolerances can VOLCRIX hold on bar turned EV charging pins?

Standard OD tolerance is ±0.01 mm on critical pin diameters. We can hold ±0.005 mm on the contact engagement zone when the Star SR-20R is run with main-spindle synchronization and in-process gauging. Length tolerance ±0.05 mm. Surface finish 0.4 µm Ra on the contact zone. Every lot is dimensionally verified on Zeiss Contura CMM with Cpk ≥ 1.33 reported on the FAI.

What plating should I specify for outdoor EV charging pins?

Silver 3–5 µm over nickel 1–2 µm is the standard stack for outdoor DC fast-charge pins. Silver gives low contact resistance at high current; nickel acts as a copper-diffusion barrier. For coastal or salt-spray environments, add a chromate conversion coating (MIL-DTL-5541 Class 3) over the silver or use tin 5–8 µm instead of silver. Salt spray per ASTM B117 at 96 h to 500 h is the typical validation scope.

What is the typical lead time for a custom EV charging pin program?

Samples: 7 to 15 working days after the PO, with first-article inspection report. Production: 3 to 4 weeks after sample approval for typical 50,000-piece lots. High-volume production (500,000+ pieces per month) runs on dedicated Star machines with a 4 to 6 week tooling and process qualification lead time.

Can VOLCRIX handle both the pin and the connector housing?

We manufacture the bar turned components and precision-machined housing bodies. We partner with Wenzhou-based injection molders and machining shops for full connector housing assembly if needed, and have shipped turnkey CCS and NACS connector assemblies under a single part number to European and US charging OEMs.

Does VOLCRIX offer Hi-Pot and partial discharge testing in-house?

Yes. Hi-Pot testing at 2500 V AC for 60 seconds is standard on every EV charging pin lot. We also run partial discharge testing per IEC 60270 for HV insulation validation, and thermal cycling per IEC 60068-2-14 from -40 °C to +125 °C. Testing reports ship with each lot in the FAI package.

Certifications & Standards