Z-Fill Connector


z axis z fill composite

Z-Fill Elastomeric Connector 

Z-Fill Elastomeric Connectors are made of tightly spaced wire filaments formed in a C or U-shape which, when compressed, create electrical contact. They have economic and performance benefits in special situations where traditional mechanical connectors are disadvantaged.

They can be insulated on two sides for electrical isolation.

To specify a custom Z-Fill Connector for your application, please complete a drawing template or contact us directly.

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Z-Fill Features & Benefits

Z-Fill Gold and Z-Fill Z-Alloy Connector Data Sheets

Wire Metallurgy

We maintain a stock of the following wire types:

  • Z-Alloy
  • Gold Plated Copper
  • Gold

We are able to build connector elements with almost any wire and will respond to special requests for materials such as Chromel, Alumel, Inconel, etc… We will also work with wire supplied by our customers, as long as the material is continuous. We also work with conductive polymer fibers.

Rubber Core

The standard core material for Z-Fill Elastomeric Connector is 50 Shore A durometer silicone rubber, with a temperature range of -45° to 125°C [-49° to 257°F]. Other choices are available for higher and lower temperatures, softer or harder durometers, and rubbers other than silicone.

Outline Dimensions and Tolerances

Measurements of outline features in an unrestrained condition are subject to variation. If necessary, use mutually designed and accepted inspection fixtures for verification of finished dimensions. Because we build our own manufacturing equipment, if your application requires a longer, shorter, wider or thinner connector, please do not hesitate to contact us with such a request. It may be a relatively simple matter to go beyond the listed standard dimensions.

The minimum standard dimensions and typical tolerances are:

Length: 0.50 mm +/- 0.250 or 0.020 inches +/- 0.010

Height: 0.50 mm +/- 0.125 or 0.020 inches +/- 0.005

Width: 0.50 mm +/- 0.125 or 0.020 inches +/- 0.005

The maximum standard dimensions and typical tolerances are:

Length: 20 cm +/- 0.250 or 8.00 inches +/- 0.010

Height: 19 cm +/- 0.125 or 7.50 inches +/- 0.005

Width: 19 cm +/- 0.125 or 7.50 inches +/- 0.005

Wire Size and Pitch

The standard, in-stock diameter wire used for Z-Axis connector elements is 0.05 mm (0.002 inch). We are able to build connector elements with almost any size or shape wire (such as ribbon) and will respond to special requests for wire or ribbon as thin as 0.01078 mm (0.0007 inch).

The pitch of wires for most Z-Axis connector elements is 0.10 or 0.125mm (0.004 or 0.005 inch). We are able to offer closer or wider spacing depending on the requirements of the application. We are able to group wires on a repeatable basis and can place wires accurately from a reference edge or other physical feature.

Learn more about our products & capabilities.

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