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Case Studies


The Problem

The customer was an electrical switch manufacturer that had a problem during assembly of their product. Solder scatter during the connector assembly process had increased costs to an unacceptable level. The scattered solder rendered these expensive electronic chips, supplied as a connector for an air conditioning unit to the automotive industry, defective, leading to a high level of rejection and a big increase in costs.

The Solution

The customer had a significant problem that was costing them dearly. Advanex were able to solve the problem through creative use of their advanced technology. We offered:

  • An innovative approach
  • Advanced processes
  • A cheap, easy solution

The customer approached Advanex with the need to develop a connector that prevented damage from solder scattering during assembly. They needed an easy way of protecting the expensive electronic device from damage.

The creativity of Advanex engineers and their proven technology made it possible to find an ideal solution. To prevent the scattering of solder during assembly, it would be useful to integrate a cover into the product. The cover should not hinder the soldering process, and removal of the cover once the component is installed needed to be easy with no risk of damage to the rest of the device.

To do this the cover needed to be attached securely but be delicate enough to allow easy removal. The main factor was the material thickness of the joint portion.

The ideal thickness could not be calculated but the engineer was able to achieve optimum performance through his own judgement.

To manufacture the product, Advanex used our double insert moulding technology. This approach to solving the problem has been passed onto Advanex staff to demonstrate the importance of creativity in finding a solution.

Advanex are proud to have developed a product that is still important to the client 15 years later.

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Insert moulding

Forming Method

Insert moulding




Switch maker


Electric board connector




3 months in development


Develop connector preventing solder scatter


Creativity, craftsmanship

Customers Benefit

Product yield improved dramatically, product

Is still effective 15 years on