How To Manufacture A Switch?

Whether installing home lighting systems or controlling industrial equipment, few components get used more often than basic on/off switches. But bringing these ubiquitous electrical devices from concept to production involves careful planning, precision manufacturing, and rigorous quality control.

Follow along as we reveal the behind-the-scenes process of crafting dependable, durable, quality switches.

How To Make An Electric Switch? Complete Process

Here’s a brief step-by-step guide explaining the electric switch manufacturing process:

1. Design Considerations 

The first step is establishing design criteria based on the switch’s intended application and customers. Will it control home lighting, operate heavy machinery or serve some other purpose? Engineers define required voltage/amperage ratings, number of poles, throw configuration, termination style, enclosure parameters and special features like illumination or waterproofing.

Regulatory requirements also guide design – switches must comply with safety and performance standards for their target countries. Special conditions like CE certification or UL listing often apply.

With criteria set, engineers create technical drawings detailing component sizes, shapes and configurations. Smart switches include circuit diagrams outlining internal electronics.

2. Material Selection 

What are electrical switches made by? The materials for each switch component get carefully selected to balance durability, electrical properties, cost, appearance and regulatory compliance.

Insulating components like bases and covers typically use durable thermoplastics that won’t crack from heat or impact. Common choices include polycarbonate, ABS and nylon. Any plastic near internal electronics or terminals requires UL94 flame retardance.

Conductive components like terminals and contacts rely on sturdy, corrosion-resistant metals with high conductivity like brass or copper. Springs and other current-carrying pieces often use specialized alloys ideal for flexibility and repeated hot-cold cycling without metal fatigue.

3. Precision Manufacturing 

With drawings finished and materials selected, it’s time to manufacture components to precise tolerances. Most metal parts get fabricated using automated CNC machining for consistency. Plastics use injection molding to quickly produce intricate, flawless shapes.

Skilled assembly technicians then bring everything together by hand or with automation, inserting and soldering any internal electronics first. Meticulous quality checks happen at multiple stages to catch defects early. Specialized tools apply exact amounts of pressure or alignment during critical construction steps.

4. Rigorous Testing 

Before shipping any switches, samples from a production run undergo rigorous benchmarks through environmental test chambers. Switches face repeated hot/cold cycling from -40° to 60°C to ensure stable performance across extreme temperatures. Continuous switching for thousands of cycles verifies mechanical integrity. 

Dielectric voltage withstands and leakage current tests guarantee insulation properties and prevent short circuits. Special test instruments also measure exact actuation and contact resistance values across thousands of operations.

Any switches not meeting specifications get rejected, with production processes adjusted to improve quality consistency. Extensive evaluations ensure every unit reliably meets or exceeds all regulatory safety and performance standards.

IGOTO Electric: Electrical Switch Supplier

Headquartered in China, IGOTO Electric has over 25 years of professional switchgear engineering and manufacturing expertise. By focusing business sales on B2B channels, IGOTO serves qualified electricians, electrical distributors, contractors, and developers rather than direct residential customers.

This focused strategy allows concentrating R&D and production efforts around heavy-duty switches meeting the advanced needs of commercial installation firms and industrial facilities. IGOTO’s in-house engineering team incorporates the latest smart technology into switches configurable for the IoT era with programmability and remote monitoring/control capacity via smartphones.

Vertically integrating the majority of its supply chain from proprietary tooling molds to specialized plastic, metal, and electronics fabrication machinery gives IGOTO enhanced quality control advantages. Rigorously optimizing every production step with automation while also leveraging select human craftsmanship lets IGOTO deliver exceptional consistency and customization capabilities.

IGOTO Electric’s over 42,000 switch, socket, outlet, and accessory products undergo continuous quality control testing through an ISO-certified process. This ensures flawless performance in real-world electrical systems – backing every switch with an industry-leading 15 year warranty.

Conclusion

Crafting quality switches requires expertise across design, materials science, precision manufacturing, quality control, and performance validation. By leveraging over 15 years specialized experience, IGOTO Electric has engineered an integrated production process enabling mass customization of durable smart switches.

Whether you need simple residential switches or advanced programmable controllers for commercial facilities, IGOTO delivers customized solutions. Their in-house engineering and ISO-certified production facilities ensure reliable performance. With an industry-leading 15-year warranty provided, IGOTO stands behind every switch.

For professional electrical contractors or supply firms seeking a long-term switchgear partner capable of growing with clients’ needs, IGOTO Electric has the engineering innovators, supply chain resources and manufacturing capacity to meet exact specifications at scale. Learn more about their capabilities or request custom quotations by contacting an IGOTO sales representative today.