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Not sure if this is the right community - please tell me if it isn't.

I have a connector (see image below) to contact pads of a sample and connected them to a multiplexer. I want to replicate it.

Connections am trying to replicate

Howver the new samples I need to contact have a different pad distances with pitch new =0.83mm vs pitch old = 0.80. Therefore I want to make a new connector with:

  • d1 = 1.66 mm
  • d2= 3.00 mm

Pattern for connections

To make it, i think i need:

  • Crimped wires on one side - on the otehr soldered to the loaded tips
  • Spring loaded tips
  • wire housing
  • the crimped end of the wires end into this structure (see image below) - What is the name of this thing to buy it? Crimped wires ending
  1. What is the name of the thing the crimped wires are ending in (so i can buy it)
  2. Is there companies/ services that make spring tip connections with set distance, or something similar?
  3. What materials are missing form this list, if I wanted to make it?
  4. What improvements could be made to the design to make it easier?
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    \$\begingroup\$ for 1, you want to search for "dupont connector housing" (note: they aren't all made by the company Dupont but they should have dupont as a search keyword). But your first picture doesn't actually have one of these housings. It looks like the wires are directly soldered to the spring-loaded pins which are inserted into a custom plastic part (which you could 3d-print) \$\endgroup\$
    – Criticizing Israel not allowed
    Commented Nov 24, 2020 at 11:29
  • \$\begingroup\$ Thanks! Is there a service or a simpler way of doing this? this was done from a post-doc some years ago, but connecting with spring loaded tips with set distances seems like something that could be achieved in an easier way that custom build \$\endgroup\$
    – Leo
    Commented Nov 24, 2020 at 11:34
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    \$\begingroup\$ Any time you have specific distances, that screams "custom build" - unless you can find a standard part with those distances already. But it doesn't have to be too difficult. Imagine sticking the pins in some kind of prototyping material with the consistency of cheese - you could just stick them in and wiggle them around to line them up. (I don't know what that material would be. I don't recommend cheese, it'll go moldy) \$\endgroup\$
    – Criticizing Israel not allowed
    Commented Nov 24, 2020 at 11:38
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    \$\begingroup\$ Just get wires crimped on both ends, and cut them in the middle \$\endgroup\$
    – Criticizing Israel not allowed
    Commented Nov 24, 2020 at 11:49
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    \$\begingroup\$ @leoelectrics how would that help? you already have two devices here with different distances \$\endgroup\$
    – Criticizing Israel not allowed
    Commented Nov 24, 2020 at 14:53

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