The RJ45 production process

The production process described here reflects only the procedures followed at our factory; it does not represent the manufacturing processes and procedures of other factories on the market. We simply wish to provide some insight into just how complex the production process behind a simple network port actually is.

(1) Automatic terminal insertion (see the diagram below for details)

Terminal insertion is the first step in the entire production process. It mainly involves arranging the eight gold-plated copper wires neatly and inserting them into the plastic body of the RJ45 connector, whilst ensuring the correct insertion angle.

(2) Terminal bending/shaping (see figure below)

Bend the inserted gold pins to the angle specified in the drawing (90° or 180°); this step creates the contact surface for the crystal connector.

 (3) LED assembly (see figure below)

Insert the LEDs into the corresponding grooves in the plastic housing, sorting them by colour and polarity. 

(4) Internal Pin Inspection (see figure below) 

This step primarily involves checking whether the gold pins installed inside the housing have any faults, focusing on four key issues: 

**1. Missing pins 

1. Bent pins 
2. Gold pins slipping out of the guide slots 
3. Scratched gold pins**

(5) LED Moulding/Hot-Melting (see figure below) 

Secure the LED leads and trim them to the same height as the leads

 (6) External Pin Inspection (see figure below) 

Check the external pins for defects, focusing on three main categories: 

**1. Missing or bent pins 

1. Deformation or scratches 
2. For SMT-type RJ45s, check for coplanarity deviation **

(7) LED Testing (see figure below) 

This step verifies whether the LED is functioning correctly, focusing on four key aspects: 

1. On/off status 
2. Forward voltage drop 
3. Correct colour display and uniform brightness
4. Polarity matches the schematic

(8) Continuity and High-Voltage Testing (see figure below) 

**Continuity test: **Primarily to confirm that each gold pin is connected to its corresponding lead 
**High-voltage test: **Primarily to verify that the insulation withstand voltage meets the standard

Now that we have looked at the manufacturing process, let's discuss a few key quality factors that determine the quality of an RJ45 connector.

 Firstly: the dimensional accuracy of the plastic body 

The precision of the body's opening - that is, the socket - directly affects the tightness and stability of the connector's insertion. Generally speaking, manufacturers strictly adhere to the FCC Part 68 specifications. Our (VOOHU) solution is to use high-precision moulds and automated injection moulding machines to reduce tolerances to within 0.25 mm. Typically, issues such as loose connections, difficulty inserting or removing the connector, and poor contact are all caused by excessive dimensional tolerances at the interface. 

Second: Co-planarity of gold pins

The solder pins on SMT-style RJ45 connectors must be perfectly horizontal; otherwise, this will result in poor soldering. 

Third: Consistency of LED parameters

Whether the LED's brightness, forward voltage drop and polarity conform to the specification sheet is crucial to whether the panel's LED indicator lights up and whether the brightness is consistent. 

Generally speaking, connector products undergo 100 per cent inspection prior to dispatch. The main test items for this comprehensive inspection are: 

**1. Continuity/short-circuit testing 

1. Contact resistance testing
2. Insulation resistance testing 
3. High-voltage withstand testing 
4. LED electrical parameter testing That concludes ** what I wanted to share in this instalment. 

I'll leave it at that for now. If there are any errors or omissions in my explanation, please feel free to point them out; I shall be grateful for your feedback. 

Are you designing an Ethernet solution? VOOHU utilises its own-brand industrial connectors, complementary magnetic components and chips to provide eight solutions for key industrial applications. Our services cover every stage from component selection and customised design through to mass production; every order undergoes an engineering review to verify the feasibility of the components and solutions.