Opportunity Source
Supplier referral. The initial opportunity originated with another supplier, who recognized Stockwell as a better technical fit and transferred the project directly to our team.
Application
Stockwell was engaged to develop custom connector dust caps and plugs for a demanding electronics application requiring:
- Integrated EMI shielding
- A tethered design, where standard EMI materials alone were not mechanically strong enough to function as the tether
- Fully custom geometries, as off-the-shelf solutions could not meet performance or design requirements
The program currently includes seven unique part designs, utilizing both liquid injection molding (LIM) with over-molding of mechanical inserts and compression molding with EMI materials.
Technical Challenge
The customer needed a solution that combined:
- Reliable EMI shielding
- Durable tether functionality
- Complex, application-specific geometries
- Manufacturability at scale
Material selection and part design were still evolving, with anticipated use of conductive EMI elastomers and LSR components. Final designs required close collaboration between engineering, materials, and manufacturing teams.
Engineering Support
Stockwell partnered closely with the customer to address a highly specialized design challenge, providing application guidance, material expertise, and manufacturability input. Stockwell supported design iterations providing production-like 3D printed Silicone caps in various geometries and materials for customer analysis and testing. The resulting solution is expected to be purpose-built and difficult to duplicate.
Advanced Manufacturing Capabilities
By leveraging both compression molding of EMI materials and LSR injection molding, Stockwell delivered a flexible production strategy to support multiple part configurations within a single program.
Investment Readiness & Scalability
Recognizing the program’s long-term potential, Stockwell demonstrated readiness to scale production capacity as demand increases—an ability that few suppliers possess for high-volume, highly customized EMI components.
Outcome
Stockwell is supporting final design validation and preparing for production ramp. Through early engineering involvement and manufacturing alignment, Stockwell positioned itself as a strategic partner for a complex, high-performance connector protection solution.
If your program involves high-reliability silicone sealing, integrated EMI solutions, or challenging qualification timelines, engage Stockwell early.
Request a rapid prototype or consult with a Stockwell application engineer to de-risk qualification and accelerate production readiness.
