Two functions need to be considered together: establishing the electrical connection and securing the contact assembly. A solder joint can contribute to both, while a housing, bracket or other mounting feature may provide additional mechanical support.
For custom equipment, we can develop pogo pin and magnetic connector assemblies from customer drawings, adapting the terminal geometry, contact arrangement, carrier and mounting features to the device. Reviewing these features together helps establish a practical electrical connection and a defined path for the mating forces.
The four arrangements below cover the common configurations described in many PCB-mounted pogo pin designs.
| Mounting arrangement | How the electrical connection is made | Main installation considerations |
|---|---|---|
| Direct surface mounting | The contact base is soldered to a PCB surface pad | Footprint, coplanarity, solder joint quality and mechanical support |
| Direct through-hole mounting | The terminal enters a PCB hole and is soldered | Hole and terminal dimensions, board thickness and underside clearance |
| Surface mounting with an insulating carrier | The carrier positions the contacts, whose bases are soldered to surface pads | Carrier attachment, contact alignment and soldering access |
| Through-hole mounting with an insulating carrier | Contacts are held in a carrier and their tails are soldered through the PCB | Alignment of tails and mounting features, retention and assembly tolerances |
For direct surface mounting, solder paste is applied to the appropriate PCB pads, the contacts are positioned, and the solder is reflowed using a process suitable for the component. The finished solder joints provide the electrical connection. Solder paste alone is not the final means of securing the parts.
SMT can be useful where the layout does not permit terminal holes or where assembly needs to fit an existing surface-mount process. The contact base, PCB footprint and placement method must support repeatable positioning.
This method should not automatically be described as mechanically weak. Its performance depends on the pad design, joint quality, board stiffness and forces applied during use. Problems arise when the solder joints carry loads beyond those considered in the design.
If a device approaches the contacts at an angle, for example, the resulting lateral load can act differently from the intended axial compression. Guides and housing supports should control the mating movement rather than rely on the soldered contact bases to correct misalignment.
Through-hole mounting uses a terminal that passes through a PCB hole before soldering. The tail can assist positioning during assembly, and the resulting joint provides the electrical connection.
The hole diameter, terminal dimensions and board thickness need to be coordinated. There must also be adequate space beneath the PCB for the protruding tail, solder joint and surrounding components.
Simply inserting a terminal into a hole does not necessarily secure it. A conventional solder tail normally requires the specified soldering operation. It should not be treated as a press-fit terminal unless the contact and hole have been designed for that process.
Through-hole soldering may use wave, selective or manual soldering where appropriate. The chosen process must remain within the thermal requirements of the actual connector. A through-hole terminal does not establish that every associated housing, spring or magnet can pass through any soldering process.
An insulating carrier can be added to a surface-mount assembly to hold multiple contacts at the required pitch and orientation. This can make handling and placement easier, particularly where individual pins would otherwise need to be positioned separately.
The carrier also helps define the relationship between the contacts. Its dimensions should control the features that matter to mating, including contact position and installed height.
Additional mechanical support depends on how the carrier attaches to the product. A carrier that only rests on the PCB does not automatically provide an independent retention path. Locating pegs may assist positioning without securing the assembly against lifting or lateral loads.
Where additional retention is required, the design may include suitable locking features, fasteners or support from the device housing. Their function should be clear in the drawing.
A through-hole connector with an insulating carrier combines contact positioning with soldered terminal connections. It can be useful where the product needs a defined multi-pin layout and a mounting structure that remains stable during assembly.
This arrangement should be assessed through its actual load paths rather than described simply as "triple reinforcement." The carrier, its attachment features and the soldered terminals may share loads differently. Some features may only locate the part, while others provide retention.
Assembly tolerances become particularly important when several tails and mounting features must enter the PCB together. Their positions need to agree with the board pattern without forcing the connector into place. Excessive assembly force can distort parts or load the terminals before the product is used.
A carrier can add parts or tooling cost, but it may also simplify handling and inspection. The overall cost should include assembly effort, process consistency and service access rather than only the price of the plastic component.
Across all four arrangements, working height is a critical dimension. The mounting method establishes the position of the pogo pin relative to its mating surface, so PCB location, carrier dimensions and enclosure tolerances all affect compression.
The minimum installed compression must still provide adequate contact force. The maximum must stay within the permitted working range. Mechanical stops should establish the final position without forcing the contacts to their travel limit.
The combined spring force also matters. A multi-pin connector can place a substantial load on the PCB or mating module. The board and mounting structure should provide the support needed to maintain alignment without excessive movement.
Electrical requirements may influence the mounting choice as well. For a power interface, the contact termination, PCB copper and solder joint must support the intended load. For a data interface, the contact arrangement and PCB transitions need to suit the required signals.
Other installation methods are possible where PCB mounting does not suit the product. A wire-terminated contact may be mounted in a housing or panel, for example. In these designs, the electrical termination and mechanical fixing still need to be specified separately.
Before approving the installation, evaluate a representative assembly for:
- Contact position and installed height.
- Correct compression across the tolerance range.
- Solder joint quality and electrical continuity.
- Voltage drop and temperature where power is carried.
- Mating alignment and structural support.
- Performance after the specified mechanical or environmental tests.
The manufacturing drawing should identify the PCB footprint or hole pattern, terminal dimensions, carrier attachment and soldering requirements. Inspection criteria should then focus on the dimensions and joints that control fit, contact operation and electrical performance.
1. Is SMT mounting always less secure than through-hole mounting?
No. Mechanical performance depends on the complete design, including the solder joints, PCB and supporting structure. Either method can be unsuitable if mating forces or handling loads are not properly addressed.
2. Does a through-hole pogo pin need soldering?
A conventional solder-tail design normally does. Insertion into the hole mainly positions the terminal before soldering. A specifically designed press-fit contact follows a different installation requirement and should not be confused with a solder-tail part.
3. Does adding a plastic carrier automatically provide extra retention?
No. The carrier positions the contacts, but its contribution to retention depends on how it is attached. Locating features, locking features and structural supports perform different functions and should be identified in the design.
4. Which mounting method is best for a frequently used charging dock?
Choose the arrangement that supports the electrical load, required contact height and expected mating forces. The dock should guide and support the device so that the pogo pins remain correctly compressed. Verify the selected mounting arrangement in the complete assembly.
