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What DFM Issues Have You Hit with RJ45 Connectors in Production?

I've been looking at common manufacturing issues with RJ45 connectors:

  • SMT coplanarity causing opens after reflow
  • PCB-mount connectors with solder joint cracks from cable insertion force
  • Batch testing missing defects that 100% testing would catch
  • Bent pins from poor packaging

What DFM problems have you run into with Ethernet connectors? Any fixes you've standardized on?

Full DFM guide: https://voohuelectronic-ux.github.io/voohu-rj45-guide/resources/rj45-design-for-manufacturing.html

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