Magnetic Connector, Cable Assembly & Pogo Pin FAQ

A magnetic connector is the mating interface or connector component. A magnetic cable assembly includes the connector plus cable conductors, cable length, outlet, mechanical protection and the opposite-end termination.

Start from the Magnetic Connector catalog when your team controls the final wiring. Start from the Magnetic Cable Assembly catalog when CTP must supply the complete cable.

An individual pogo pin is one spring-loaded contact. A pogo pin connector combines multiple contacts with a housing or alignment structure. Choose individual contacts when your team designs the surrounding holder or PCB arrangement; choose a connector assembly when the contacts must arrive as an aligned multi-contact component.

Use a magnetic interface when self-alignment, low insertion effort, controlled release or a detachable cable experience is part of the device requirement. Use a non-magnetic pogo pin connector when retention is provided by the enclosure, latch, fixture or board structure.

The choice should be based on mating behavior and mechanical architecture, not only on appearance.

Use the Solutions Hub when the application and operating conditions are known but the product family is not. Use the Engineering Guides when the supply scope, pin count or electrical route requires a structured selection process.

Possibly, when the pin map, electrical load, available space, mating direction, magnetic behavior, cable scope and environment are compatible. A similar appearance alone is not enough. At minimum, fit, compression, polarity and electrical conditions should be reviewed before adoption.

List every independent electrical path: power, return, detection, identification, enable, control, signal and selected data. Then review whether any path requires a separate return, parallel contact or contact sequencing. The resulting contact budget determines the minimum pin count.

For a full workflow, use the Magnetic Connector Selection Guide.

No. Current capability depends on which contacts are assigned in parallel, contact geometry, resistance, spring force, working compression, cable conductor, duty cycle, ambient temperature and allowable temperature rise. Pins used for detection or signals do not increase the power-path capacity.

They can be evaluated in parallel, but equal current sharing should not be assumed automatically. Contact resistance, compression, pad flatness, wiring symmetry and thermal conditions affect how the current divides. Validation should measure the complete path rather than multiplying one pin rating by the number of pins.

Yes, separate contacts can be assigned to different functions. Confirm the protocol, data rate, return path, shielding, grounding, contact spacing, sequencing and cable construction before calling the interface suitable for data. Not every magnetic layout or cable supports every signal.

Current is limited by the complete thermal path: contacts, compression, cable conductors, terminations, PCB pads, housing, duty cycle and ambient temperature. Voltage capability depends on spacing, insulation, materials, contamination, environment and the applicable safety requirements of the final product.

Measure or calculate the complete loop, including both mating contacts, conductor length, terminations and board or device-side paths. Use the actual continuous and peak load, duty cycle and installation temperature. A component-only resistance value is not enough to predict the device result.

Open the High-Current Magnetic Cable Guide when loss or temperature is a primary design concern.

Sequencing may be relevant when ground, enable, detection or power paths should connect or disconnect in a controlled order. It requires deliberate differences in contact height, stroke, pad geometry or system logic and must be validated with the actual mating motion.

Working compression is the amount the plunger is depressed in the normal mated condition. It determines contact force, available tolerance, electrical stability and remaining travel. Too little compression can cause intermittent contact; too much can damage the spring or increase the required magnetic holding force.

A mechanical stop prevents the pogo pin from being compressed beyond the approved travel during assembly, impact or user force. The stop should be defined by the enclosure or mating structure rather than relying on the internal spring to absorb unlimited over-travel.

Specify the required holding or release force in newtons, the pull direction, cable angle, device mass and intended user interaction. The final force depends on magnet arrangement, air gap, housing material, mechanical guidance and the combined spring reaction of all compressed contacts.

Use a combination of magnet polarity, asymmetric geometry, keys, guide features, contact layout and electrical protection. Magnetic polarity alone may not prevent every incorrect rotation or shifted engagement, especially in round or symmetrical interfaces.

A round structure may suit rotationally symmetric products, circular charging docks or designs that need a central contact. A linear structure may simplify PCB routing, orientation control and contact allocation. The decision should follow enclosure geometry, mating direction, pin map and anti-rotation requirements.

Include housing flatness, pogo pin height, PCB/FPC position, adhesive or molding thickness, magnet position, pad height, device gap, assembly variation and expected wear. The stack should keep every contact within its approved working-compression window.

Pogo pins are primarily designed for axial compression. Excessive lateral motion can bend the plunger, scrape internal surfaces, damage plating or make the plunger bind in the barrel. Add mechanical guidance so the housing absorbs alignment loads before the contacts compress.

Longer or smaller conductors increase resistance, voltage drop and heat. The cable should be selected from current profile, allowable voltage loss, flex requirements, outer diameter, termination and installation temperature. The same connector can perform differently with a different cable.

Define USB type, bare wire, board connector, FPC, custom plug or other termination; also provide pin-to-wire mapping, cable length, outlet direction, overmolding, shielding and labeling requirements. A cable drawing should document both ends, not only the magnetic side.

Review the cable bend immediately after the connector, expected pull direction, enclosure clearance, user handling and repeated flexing. Strain relief should transfer load into the housing without forcing the solder joint or conductor transition to become the hinge point.

Yes, but flex pattern, bend radius, abrasion, torsion, oil or chemical exposure, vibration, drag-chain use and maintenance access must be defined. Cable material and construction should match the motion; a standard consumer cable should not be assumed suitable for machinery.

Review the Industrial Magnetic Cable Guide.

No. Release depends on force direction, cable angle, magnet layout, surface friction, device mass and obstructions. A cable may release differently in axial, peeling and sideways pulls. The intended accident or user scenario should be tested on the complete product.

Water protection depends on the complete mated or unmated interface, housing, seals, potting, cable outlet, device installation and test condition. A component may support a sealing concept, but the final IP result should be assigned only after testing the defined assembly.

Define the exposure medium, concentration, duration, temperature, drying cycle, cleaning method and acceptance criteria. Review plating, base materials, magnet coating, dissimilar-metal contact and whether voltage is present during exposure, because energized wet conditions can behave differently from a storage test.

Compatibility depends on the exact chemical, concentration, contact time, wiping method, frequency and materials used in the connector, housing, adhesive, overmolding and cable jacket. Send the cleaning protocol before material selection; “alcohol resistant” is not a universal chemical rating.

Provide operating, storage, soldering or assembly temperatures; exposure duration; temperature cycling; electrical load; and whether the magnets, plastic, adhesive, spring and cable experience the same temperature. The weakest material or process may determine the usable range.

Cycle life depends on contact geometry, plating, spring stress, working compression, pad material, contamination, alignment, side loading, current during mating and the failure criterion. A cycle number without test force, load and acceptance limit is incomplete.

Test the connector in the representative device fixture with the intended compression, cable support and electrical monitoring. Define axes, frequency or pulse profile, duration, load and what counts as a discontinuity. A loose component test may not represent the installed system.

Particles can block plunger travel, increase contact resistance or prevent the pad from reaching the intended compression. Review surface geometry, drainage, self-cleaning motion, protective covers and maintenance access. A flat interface is easier to wipe but is not automatically dustproof.

Selection depends on current, spring behavior, wear, corrosion, mating cycles, soldering, cost and regulatory constraints. Do not select plating only from a generic “gold-plated” description. Define the base material, underplate, finish, thickness range, contact area and verification method on the approved specification.

Material options can be reviewed, but “nickel-free,” “hypoallergenic” or “biocompatible” should be tied to a defined material, contact category, test method and final device use. The finished-device manufacturer remains responsible for skin-contact and regulatory validation.

RoHS and REACH relate to restricted substances and chemical obligations. CE and FCC generally apply to a finished product or system under specific directives or radio/electromagnetic requirements. A passive connector component does not automatically give the final device CE or FCC approval.

Freeze the approved 2D drawing, pin map, materials and plating, cable specification, magnet direction, critical dimensions, working height, inspection criteria, packaging, labeling and agreed change-control route. The drawing should identify which values are controlled and how they are measured.

Requirements may include lot number, material batch, inspection records, drawing revision, production date, test report, packaging label or approved supplier information. Define the required retention period and record format before mass production rather than after a field issue.

An existing platform may be adapted when housing size, pin arrangement, magnet geometry and manufacturing process remain compatible. New tooling is more likely when the outline, row structure, pitch, sealing, overmolding, cable outlet or mechanical keying changes substantially.

1. Requirement and supply-scope review.
2. Pin map, structure and DFM confirmation.
3. Drawing and material approval.
4. Prototype or sample build.
5. Project-specific electrical, mechanical and environmental validation.
6. Pilot build, inspection-plan confirmation and production release.

Lead time depends on tooling, custom machined parts, magnets, plastics, cable materials, drawing revisions, sample quantity, assembly process, test requirements and approval speed. It should be confirmed after DFM review rather than promised from the product category alone.

MOQ can be influenced by custom tooling, contact quantity, cable and material purchasing multiples, molding or assembly setup, inspection, packaging and whether an existing platform is used. Prototype quantity and production MOQ should be quoted separately.

Check fit, mating direction, polarity, compression, magnetic holding and release, pin continuity, cable mapping, voltage drop, temperature rise under the intended load, strain relief and relevant environmental risks. Do not approve only from appearance or basic continuity.

Use drawing revision control and define which material, dimension, process, supplier or test changes require customer notification or approval. Keep the approved sample and production inspection criteria aligned with the latest released revision.

Common causes include insufficient compression, tolerance stack, contamination, side loading, pad wear, cable movement, weak termination, incorrect pin map, unstable power source or vibration. Record the device orientation, load, motion and waveform when the failure occurs.

Possible causes include excessive current, high contact or termination resistance, unequal parallel-contact sharing, undersized conductors, poor compression, contamination, long cable length or insufficient heat dissipation. Measure temperature and voltage drop at multiple points to locate the dominant loss.

Causes may include over-compression, lateral load, contamination, corrosion, plunger deformation, damaged internal surfaces or material degradation. Inspect the housing guidance and compression stop before replacing the pin with a stronger spring.

Check magnet grade and dimensions against the drawing, pole direction, air gap, housing material, assembly position, temperature exposure, surface flatness and the opposing spring force. Measure release force using the specified pull direction and fixture.

Possible causes include sweat, condensation, cleaning chemicals, dissimilar metals, porosity or damage in the finish, contamination, energized wet conditions or residue from assembly. Record the environment and analyze both the contact and mating pad before changing plating.

The outlet may be acting as a repeated hinge or carrying pull load into the conductor or solder joint. Review bend radius, strain-relief length, cable stiffness, overmolding transition, pull direction and the real use motion. A stronger outer jacket alone may move the failure to another point.

• Application and device description.
• Required product family or uncertain supply scope.
• Pin map and contact functions.
• Voltage, continuous current, peak current and signal requirements.
• Available length, width, height, PCB/FPC position and mating direction.
• Cable length, outlet, conductor and opposite-end termination when required.
• Target magnetic holding or release behavior.
• Water, sweat, cleaning, temperature, vibration and lifecycle conditions.
• Prototype quantity, expected production quantity and available 2D/3D files.

STEP or IGES files help review the 3D envelope and assembly. A dimensioned 2D drawing is needed for controlled dimensions, tolerances and inspection. A pin map, cable diagram, PCB/FPC layout and section view are also useful. Images are helpful for context but should not replace production drawings.

Yes. Mark confirmed values, target values and unknown items separately. An early review can identify the likely product route and missing inputs, but final drawings, pricing, tests and schedule should wait until the critical electrical and mechanical requirements are sufficiently defined.

Use the Get Quote & Samples page to submit the application, product family, quantity, requirements and files. Use Technical Support for troubleshooting or an existing connector-integration question.