Custom Magnetic Connector Solutions for OEM & ODM Device Engineering
Use this solutions hub to route a device project from system requirements to the correct magnetic connector, magnetic cable assembly, pogo pin connector or individual spring-loaded contact. The selection starts with the electrical interface, installation geometry, user interaction, operating environment and production plan—not with appearance or pin count alone.
- Electrical functions and pin map
- Mechanical envelope and mating direction
- Cable, PCB or FPC supply scope
- Environment, lifecycle and validation
Choose the Correct Product Family Before Selecting a Pin Count
These four product families solve different parts of the interconnect system. Selecting the wrong supply scope early can create repeated redesign of the cable, housing, PCB, strain relief or final assembly.
Magnetic Connectors
Choose this route when the project requires the magnetic mating components and device-side interface, while the customer controls the final cable, PCB or internal wiring integration.
- Custom pin count and layout
- Linear, round or multi-row structure
- PCB, FPC, wire or custom mounting
Magnetic Cable Assemblies
Choose this route when CTP must supply the connector together with cable conductors, length, termination, overmolding, outlet direction and strain relief.
- USB, bare wire, PCB or FPC end
- Wire gauge and voltage-drop review
- Cable routing and mechanical protection
Pogo Pin Connectors
Choose a non-magnetic connector assembly when spring-loaded contacts, housing, pitch and board/device mounting are required without a magnetic mating system.
- Single-row or double-row arrays
- Custom housing and pitch
- Board, wire, FPC or device integration
Individual Pogo Pins
Choose individual spring-loaded contacts when your engineering team will design the surrounding housing or PCB structure and only the contact is supplied.
- SMD/SMT, DIP and right-angle types
- Double-ended and custom contacts
- Stroke, spring force and plunger design
Build a Contact Budget Before Choosing 2 Pin, 4 Pin or Multi-Pin
Pin count should be the result of the circuit allocation. A visually similar connector may require a different number of contacts because of separated returns, detection, control, communication or future reserved functions.
Contact-budget workflow
- List the primary power paths Identify supply and return paths, operating current, peak current and whether parallel contacts may be required.
- Add functional channels Include charging detection, identification, enable, control, sensing, communication and other independent circuits.
- Separate sensitive or high-load paths Review whether signal ground, high-current return or sequencing contacts need independent allocation.
- Review reserved and manufacturing contacts Consider future functions, programming, testing or identification only when they are genuinely required.
- Check whether the layout fits the mechanical envelope A valid circuit allocation may still require a round, multi-row or custom high-density structure.
Connector Requirements Must Be Reviewed as a Connected System
A change to one parameter often moves several other design decisions. Reviewing these relationships early reduces late-stage changes to tooling, cable construction, PCB layout and validation.
Current Path & Thermal Performance
- Current profile
- Contact allocation
- Conductor size
- Voltage drop
- Temperature rise
Current capability cannot be judged from pin count alone. Continuous load, peak duration, cable length, contact resistance, conductor size, ambient temperature and cooling conditions must be reviewed together.
Open High-Current Cable GuideMagnetic Force & Contact Compression
- Spring force
- Number of contacts
- Magnet layout
- Air gap
- Release behavior
The magnetic system must overcome the combined spring reaction while still providing the required release force. Housing guidance, polarity and device mass also affect the final user experience.
Sealing & Serviceability
- Exposure
- Housing interface
- Potting or molding
- Cable outlet
- Repair strategy
Water or dust protection belongs to the complete mated assembly. Stronger sealing may change serviceability, manufacturing sequence, tolerance and inspection requirements.
Signal Requirement & Physical Layout
- Signal type
- Pin assignment
- Grounding
- Spacing
- Cable construction
Not every magnetic connector or cable is suitable for every signal. Protocol, frequency, shielding, return path, contact sequence and cable movement should be confirmed before calling a structure a data connector.
Continue to the Industry Page That Matches the Operating Conditions
The following pages focus on application-specific risks and project inputs. This hub does not repeat their detailed content; it routes the project after the basic connector architecture is understood.
Automotive Electronics & E-Mobility
Use this route for low-voltage vehicle electronics, light electric mobility, removable modules, charging docks and in-cabin devices.
Open Automotive SolutionMedical Devices & Healthcare Equipment
Use this route for portable equipment, monitoring accessories, diagnostic tools, rehabilitation devices and charging or docking systems.
Open Medical Device SolutionSmart Home & IoT Devices
Use this route for smart locks, sensors, robotic appliances, security devices, charging docks and connected household hardware.
Open Smart Home & IoT SolutionWearables & Consumer Electronics
Use this route for smartwatches, TWS earbuds, smart rings, AR/VR devices, personal electronics and compact charging accessories.
Open Wearable SolutionUse the Detailed Guide for the Decision You Are Making Now
The site already contains separate guides for supply scope, pin count, high-current design, industrial cable integration and wearable charging. Select only the guide that matches the current project question.
Magnetic Connector Selection Guide
Use when the correct pin count, connector shape, contact allocation or mating structure has not yet been confirmed.
Open Connector SelectionMagnetic Cable Selection Guide
Use when deciding between a connector component and finished cable, or when cable length, conductor, termination and routing remain undefined.
Open Cable Selection1–3 Pin Connector Guide
Use when evaluating basic power paths, special one-contact structures or an additional detection, control or identification contact.
Compare 1–3 Pin4 Pin vs 5 Pin Connector Guide
Use when power and return must be combined with additional signal, control, detection or reserved channels.
Compare 4 Pin and 5 Pin6 Pin & Multi-Pin Guide
Use when the interface requires six or more defined contacts, multiple rows, a dense PCB area or complex channel allocation.
Review Multi-Pin Layouts1–2 Pin Power Cable Guide
Use when the cable primarily carries a simple supply and return path and cable length or voltage drop still requires review.
Review Power Cable Design3 Pin vs 4 Pin Cable Guide
Use when the finished cable combines charging power with detection, identification, signal or control contacts.
Compare 3 Pin and 4 PinIndustrial Cable Application Guide
Use for machinery, handheld terminals, fixtures and equipment where cable movement, abrasion, vibration, contamination and maintenance matter.
Open Industrial GuideSmart Wearable Charging Guide
Use for compact packaging, lightweight cable routing, sweat exposure, user-facing docking and controlled magnetic release.
Open Wearable GuidePlan Connector Validation by Project Stage
A connector may pass a component check but still fail after being integrated into the device. Organize validation around the maturity of the product and freeze the correct information at each stage.
Architecture & EVT
Confirm that the selected concept can satisfy the basic system requirements.
- Pin map and supply scope
- Fit, mating direction and compression
- Preliminary current and temperature review
- Magnetic alignment and release direction
- Initial cable routing and strain relief
DVT & Reliability
Validate the integrated device against the intended use and environment.
- Contact resistance and continuity
- Temperature rise and voltage drop
- Mating cycles and contact stability
- Pull, vibration, shock or movement
- Water, sweat, corrosion or cleaning exposure
PVT & Production Control
Freeze the production specification and establish repeatable inspection.
- Approved drawing and material list
- Critical dimensions and tolerances
- Pin height, polarity and force checks
- Electrical and appearance inspection
- Packaging, traceability and change control
Information Needed from Electrical, Mechanical and Manufacturing Teams
A useful connector inquiry is not only a purchasing request. It should combine the circuit, enclosure, cable, user and production requirements into one review package.
| Owner | Information to provide | Connector decisions affected | Recommended file or format |
|---|---|---|---|
| Electrical Engineering | Voltage, current profile, power and return paths, detection, control, signal and selected data requirements | Pin count, contact allocation, conductor size, grounding, thermal and signal review | Pin map, block diagram, interface table |
| Mechanical Engineering | Available envelope, PCB/FPC position, mating direction, housing tolerance, compression and device mass | Connector shape, pitch, rows, alignment, magnets, mounting and release behavior | STEP/IGES, 2D drawing, section view |
| Industrial Design / UX | User docking method, visibility, orientation, one-hand use, release direction and surface requirements | Blind mating, round vs linear layout, holding force, cable outlet and cosmetic integration | Use scenario, render, interaction notes |
| Reliability / Quality | Operating environment, lifetime target, water, sweat, cleaning, corrosion, temperature, vibration and inspection needs | Materials, plating, sealing, validation plan, acceptance criteria and traceability | Test specification, risk list, control plan inputs |
| Manufacturing / Procurement | Prototype quantity, pilot build, annual volume, assembly process, packaging and target schedule | Tooling route, automation, termination, inspection method, MOQ and production planning | Forecast, build plan, assembly flow |
Review Existing Application Patterns Before Starting a New Design
Case pages can help teams identify useful architecture patterns, but their dimensions, materials and performance should not be copied into a new project without confirming the new device conditions.
Use the Right Resource After the Project Route Is Clear
Questions About Routing a Custom Connector Project
Should I start from an industry page or a product category?
Start from an industry page when the operating environment and user scenario are the main unknowns. Start from a product category when the supply scope and connector type are already confirmed. Use the engineering guides when pin count, cable structure or electrical allocation is uncertain.
What is the minimum information needed before selecting a pin count?
List the independent power, return, detection, identification, control and signal paths. Also provide the installation envelope, current and voltage, mating direction and whether a complete cable must be supplied.
When does a project need a custom multi-row connector?
A multi-row or custom array should be evaluated when the required contact count cannot fit the available area, when different contact functions need separation, or when the PCB and mating geometry do not suit a simple linear layout.
Why can the same connector need different validation in two devices?
Device enclosure, cable length, current profile, compression, magnetic gap, temperature, contamination and user behavior can change the result. The complete assembly and intended use determine the validation conditions.
Can a case-study solution be reused directly?
A case study can provide an architecture reference, but dimensions, electrical ratings, materials, force and environmental design should be reviewed again for the new device. Reuse should begin with a fit and DFM review.
What should be frozen before pilot production?
Freeze the approved drawing, pin map, materials, cable specification, critical dimensions, magnetic direction, inspection criteria, validation limits, packaging and engineering-change process before production release.