Case Overview
An automotive electronics Tier 1 supplier producing sensor modules and connector systems was losing yield because a low-cost supplier delivered inconsistent strip thickness and wire diameter. Out-of-tolerance strip produced terminals with insufficient contact force, causing intermittent contact failures during thermal cycling. Sensor leads with uncontrolled resistance drifted outside module calibration windows.
DZX qualified as a single auditable source for precision strip and fine wire: terminal stamping strip was held at 0.12 mm ±0.005 mm, while sensor-lead alloy wire was drawn with controlled resistance per meter. The Tier 1 supplier’s stamping yield recovered within two production quarters.
This case summarizes the application requirements, materials supplied by DZX and delivery value. For case-specific technical data, please contact our engineering team.
| Item | Details |
|---|---|
| Client Profile | Automotive electronics Tier 1 supplier (sensor modules and connector systems) |
| Project Scale | Millions of stamped terminals and sensor leads per year |
| Application | Terminal stamping strip, sensor leads and connector hardware |
| Materials Supplied | CuNi precision alloys, thermocouple alloys and copper alloy strip |
| Supply Forms | Strip, wire and flat wire |
| Lead Time | Qualification batches: 2 weeks; production batches: 3-4 weeks |
| Project Country | Germany |
| Project Year | 2025 |
Our Solution
The previous supply chain failed three measurable requirements, each directly linked to field failures and rework:
- Strip thickness drift: 0.12 mm terminal stamping strip varied by ±0.015 mm, causing inadequate terminal contact force and thermal-cycling failures.
- Wire resistance variation: sensor-lead resistance per meter varied by more than ±3%, pushing finished modules outside calibration windows and requiring individual module trimming.
- Documentation gaps: inconsistent chemistry and hardness reports complicated the Tier 1 supplier’s PPAP (Production Part Approval Process) submissions.
DZX organized supply around measurable, auditable parameters:
CuNi precision strip was rolled to 0.12 mm ±0.005 mm, with documented hardness and surface condition for consistent stamping and plating. Fine alloy wire for sensor leads was drawn with controlled resistance per meter and verified by batch; thermocouple alloy wire covered temperature-sensing applications. Each batch included chemistry, dimensional and resistance reports formatted for the customer’s PPAP documentation.
| Material | Representative Grades | Key Properties | Available Forms |
|---|---|---|---|
| CuNi precision alloys | 6J40, CuNi10-30 | Stable resistance and elastic properties | Strip, wire and flat wire |
| Thermocouple alloys | K, T, E | Temperature sensing | Fine wire and cable |
| Copper and Copper Alloys | C1100, C17200 | Conductivity and contact reliability | Strip and wire |
View CuNi Alloys → | View Copper and Copper Alloys → | View Thermocouple Alloys →
Sensor leads and connector terminals
Exhaust-gas and catalyst-bed temperature measurement
Terminals, busbars and conductive components
Technical Specifications
Key technical parameters agreed before production. Contact us for grade-specific datasheets and tolerance-verification reports.
| Parameter | Agreed Specification | Verification Method |
|---|---|---|
| Terminal strip thickness | 0.12 mm ± 0.005 mm | Micrometer, sampling from each coil |
| Strip hardness (delivery condition) | To drawing (half-hard/hard) | Vickers hardness report |
| Sensor-wire resistance | ±3% of nominal Ω/m | Batch resistance testing |
| Wire diameter (fine) | 0.08-0.5 mm, ±0.003 mm | Laser diameter measurement |
| Surface condition | Oil-free, clean and ready for plating | Cleanliness + visual inspection |
Each supplied batch includes a quality inspection certificate with chemical analysis, meeting the applicable standard for each grade.
| Material | Applicable Standards |
|---|---|
| CuNi precision alloys | GB/T 1234, ASTM B151 |
| Thermocouple alloys | IEC 60584-1 |
| Copper alloys | ASTM B187, B194 |
| Quality System | Quality inspection certificate including chemical analysis |
Delivery and Quality Support
- Fast delivery: Sample and production lead times follow the project schedule; standard grades and sizes can be dispatched promptly from stock.
- Quality traceability: Every batch includes material certificates and inspection reports, with full heat and batch traceability.
- Technical support: Responsive support covers pre-sale material selection, drawing review and post-sale processing advice.
- Ongoing service: Regular follow-up after delivery tracks performance and addresses feedback promptly.
Customer Feedback
- Stamping yield recovered: consistent 0.12 mm strip eliminated terminal contact-force defects within two quarters
- Calibration drift eliminated: resistance-controlled wire ended individual module trimming on the sensor line
- PPAP-ready documentation: chemistry, hardness and dimensional reports in a consistent format
- Supporting millions of parts: stable 3-4-week production lead times
- Single auditable source: strip, wire and thermocouple alloys under one quality system
- Fast qualification: sample batches delivered in 2 weeks for stamping and assembly trials
Our Capabilities
Jiangsu DZX Technology Co., Ltd. (Changzhou DLX Alloy) was founded in 2016. Its core team has worked in the field since 2002, with 24 years of precision-alloy R&D and production experience, operating a self-owned 12,000-square-meter modern factory with an ISO9001 system covering three inspection stages. Annual alloy output exceeds 1,200 tonnes, serving 1500+ business customers worldwide. The company operates integrated melting, drawing, annealing and precision-machining workshops, supporting volume customization of strip, wire, tube and bar. Every batch includes a chemical analysis report (MTC) for full delivery-quality traceability.
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