NACS (Tesla) Charging Pin Manufacturing: Requirements and Process

With NACS (SAE J3400) rapidly becoming the dominant charging standard in North America, more charging gun manufacturers are looking for suppliers who can machine NACS-compatible pins. Here’s what makes NACS pins different and what you need to know about manufacturing them.

How NACS Pins Differ from CCS Pins

NACS uses a 5-pin configuration — 2 combined power/DC pins, 2 signal pins, and 1 ground — all in a much more compact housing than CCS. This compact design has several implications for pin manufacturing:

• Tighter tolerances — Pins are packed closer together, so dimensional error tolerances are tighter. We typically hold ±0.01mm on critical diameters.
• More aggressive retention features — NACS pins use retaining grooves and snap-ring features that require precise undercut machining.
• Longer pin bodies relative to diameter — The aspect ratio is higher, which favors Swiss-type turning over standard CNC.
• Burr-free requirements are critical — Any burr in a compact connector can cause intermittent contact or shorting.

Materials for NACS Pins

The same copper alloy principles apply: C11000 for maximum conductivity on power pins, C26000 brass for cost-effective AC-only pins, and C17200 beryllium copper for spring-loaded or high-durability designs. Most NACS pins we machine use C11000 or C14500 (tellurium copper) with silver plating.

Manufacturing Process

NACS pin production typically follows this workflow:

1. Material qualification — Mill test report verification for each batch
2. Swiss CNC turning — Single-setup machining on sliding-headstock lathes
3. In-process inspection — Dimensional checks at defined intervals
4. Deburring — Critical for NACS pin reliability
5. Plating — Usually nickel underplate + silver flash
6. Final CMM inspection — 100% of critical dimensions
7. Packaging and shipping — Anti-tarnish packaging for plated pins

For a full comparison of connector standards, see our CCS vs NACS vs Type 2 guide. For material selection, check our copper alloy guide.

Frequently Asked Questions

Frequently Asked Questions

What material for NACS pins?

Most NACS pins use C11000 or C14500 with silver plating for maximum conductivity.

What tolerance for NACS pins?

±0.01mm on critical diameters due to compact pin spacing.

Can you make NACS pins for non-Tesla brands?

Yes. NACS is an open standard (SAE J3400). We machine NACS pins for multiple connector brands.