Connector Housing Defect Detection

Connector housings protect delicate pins and maintain precise alignment during mating. Any defect in the housing (a crack, excess flash, a chip, or a short shot) can compromise the connector's mechanical integrity and electrical performance. In the connector industry, the plastic housing is as critical as the metal terminals: it provides terminal position assurance, environmental sealing, and the mechanical interface that enables thousands of mating cycles.

These defects are especially challenging to inspect because they occur on complex 3D surfaces with varying colors, textures, and geometries. What looks acceptable from one angle may reveal a critical defect from another. Modern connector housings feature intricate geometries: locking tabs, polarization keys, wire seal interfaces, and terminal retention features, all of which must be defect-free for reliable operation.

Injection molding defects are particularly costly in connector manufacturing. A cracked locking tab means the connector won't stay mated in a vibrating automotive environment. Flash on a mating surface prevents proper sealing. A short shot on a terminal cavity means terminals won't seat correctly. These defects cause field failures, warranty claims, and in safety-critical applications, potential recalls. Overview AI catches them before they ship.

• ✓Cracks can propagate under stress, causing field failures during thermal cycling or vibration
• ✓Flash can prevent proper mating, compromise IP67/IP68 sealing, or cause shorts between terminals
• ✓Chips on keying features can allow improper mating with wrong connector type
• ✓Warpage and dimensional issues cause terminal alignment and mating force problems