Case Study: Engineering and Industrialization of Optimized Contact Spring Design for Automotive Lighting

RPK Group integrates FEM/FEA analysis, advanced materials, high-precision tooling, and cleanroom technology to optimize the performance and integration of contact springs in automotive PCB assemblies.

13/03/2025

By Egoitz Crespo, Product Manager at RPK Group, and Mikel Ortigosa, Product Engineer at RPK Technological Center

At RPK Group, we specialize in the design and industrialization of precision-engineered components for automotive lighting systems. Our engineering teams collaborate closely with clients to develop custom contact springs that enhance conductivity, elasticity, and manufacturability. In this case study, we addressed the challenge of creating a high-performance contact spring for PCB integration in headlamp lighting applications.

The Challenge: Optimizing a Contact Spring for Automotive PCB Assemblies

Our customer needed an optimized contact spring for a headlamp lighting system, ensuring consistent electrical contact between the PCB plate and the power source. The key objectives were:

Enhanced elasticity and conductivity for reliable performance
Optimized material and plating selection to improve efficiency
Precision tooling for manufacturability at scale

Our engineering team achieved these goals by leveraging advanced simulation technologies, cutting-edge material science, and high-precision production techniques

FEM/FEA-Driven Shape Optimization

Using ANSYS-based FEM/FEA simulations, our engineers developed an optimized contact spring that meets stringent automotive and PCB assembly requirements.

Key Engineering Steps:

Material and Load Definition: Ensured compliance with electrical conductivity standards and mechanical stress requirements.
Geometric Adjustments: Simulated and refined thickness, width, radius, size, and wave count to achieve the optimal balance between contact pressure and durability.
Performance Testing: Multiple iterations allowed us to minimize stress concentrations and maximize reliability in high-vibration environments.

Material Characterization and Plating Selection for Optimal Conductivity

Our Material Engineering team carefully selected the most suitable raw materials and coating processes to ensure:

Superior elasticity and conductivity for enhanced electrical performance
Corrosion resistance to extend product lifespan
Efficient manufacturability to streamline large-scale production

To achieve optimal material selection, RPK Group can characterize materials through tensile testing, ensuring the best combination of mechanical and electrical properties for each application.

We enhanced the spring’s wear resistance and electrical contact stability by integrating specialized plating technologies.

High-Precision Manufacturing and Prototyping

To ensure high-accuracy production, RPK developed:

State-of-the-art multi-slide tooling for complex geometries
Advanced stamping and forming techniques to achieve repeatable precision
Process control systems to maintain tight tolerances

Before mass production, RPK Group leveraged soft tooling technology to manufacture prototypes, allowing design validation under actual application conditions. This approach ensured the final component met all performance and manufacturing requirements before full-scale production.

Our RPK Technological Center was key in developing tooling solutions that support mass production without compromising quality.

Seamless Integration into Automotive PCB Assembly Lines

A critical project phase was ensuring the optimized contact spring could be seamlessly integrated into the customer’s automated assembly line.

Tape & Reel Packaging Solution: Enabled efficient automated feeding into high-speed PCB assembly machines.
CleanRoom Compliance: RPK Group invested in state-of-the-art CleanRoom technology for packaging and handling to meet stringent cleanliness requirements.

Conclusion: Precision-Engineered Contact Springs for Automotive Applications

Through a combination of FEM/FEA simulations, material science, precision tooling, and cleanroom technology, RPK Group successfully developed a high-performance contact spring for automotive lighting systems.

This case study highlights our expertise in designing automotive-grade contact springs, which ensure optimal performance, durability, and seamless integration into PCB assemblies.