Project description

Electrical connectors are key components of our connected world – found in cars, machines, and smartphones alike. Yet their production is facing a major transformation: lead, long used in brass alloys to improve machinability and formability, will soon be banned. This change fundamentally alters material behavior – with direct consequences for the quality, durability, and reliability of electrical connections.

A new research project by the Manufacturing Technology Institute (MTI) of RWTH Aachen University in collaboration with ETH Zurich is tackling this challenge. Its goal is to understand and digitally map the entire manufacturing chain – from casting and wire drawing to machining and crimping. By combining advanced simulation methods with experimental investigations, the project aims to identify, model, and reduce uncertainties that occur throughout the production process.

At the heart of the project lies the development of a digital process chain model that enables reverse optimization: starting from the desired properties of the crimp connection – such as electrical conductivity, pull-out force, and process time – the model determines the optimal material and process parameters. Artificial intelligence and data-driven surrogate models help capture complex interdependencies quickly and accurately.

The project makes a vital contribution to the sustainable and reliable manufacturing of lead-free connectors. It lays the foundation for more efficient production processes, resource savings, and enhanced industrial competitiveness across the entire value chain – from material design to electrical connection technology.

Process chain