Product development, from individual components to finished systems

A connector housing that warps during cooling will become apparent, at the latest, during production tooling. By then, making corrections is expensive, and the schedule is already tight. KE Elektronik therefore uses computer-aided calculation and simulation systems to identify critical areas early on and make design adjustments.

In addition to its expertise in production engineering, KE Elektronik has the experience and knowledge required for product development—from individual plastic and metal components to the resulting system. Injection molding simulations reveal weld lines, warpage, and the correct location of the gate. FEA calculations determine insertion forces, locking mechanisms, and long-term mechanical stress.

Our prototyping process produces durable prototype parts that you can actually use for testing. These are manufactured using prototype molds or additive manufacturing, depending on which property needs to be tested. The product development process follows APQP, from feasibility assessment through prototyping to SOP.

In many engineering departments, the focus is heavily on technical optimization. However, it can happen that a component—while perfectly designed on paper—cannot always be assembled in a cost-effective manner.

At KE Elektronik, production engineering is housed in the same building. Those who design a component are also familiar with the tools and equipment that will later be used to manufacture and assemble it.

Tooling, plant engineering, and testing technology are all part of our in-house operations. As a subsidiary of Amphenol Corporation, we also have access to a global portfolio of contact systems, rather than starting every project from scratch. This significantly shortens development time without compromising on customer-specific solutions.