Wire Welded Electrical Contacts vs Rivets

Checon has recently seen an uptick in interest from some of our biggest customers to change their electrical contact specification on select devices from rivets to a wire welded contact design.  Their reasons range from functionality, repeatability, quality and economics.  This last factor is the chief motivator with purchasing and engineering teams increasingly tasked to drive further cost reductions. Many are finding that wire welded electrical contacts vs rivets can deliver a viable ROI over in-house riveting operations and, in some cases, over purchased rivets where the need for improved quality is at play.

Wire welded electrical contacts vs rivets – why are so many of our customers thinking about switching?


There has always been a strong argument to switch from the engineering side. After all, the attachment is a direct weld versus a mechanical press fit, allowing for better conductivity of both electrical energy and heat. By shear testing 100% of parts produced, the integrity of the weld is assured.

Supply Chain Management

When a high-speed wire weld process is used, buyers reduce three SKU’s to one. This cuts the number of purchased components in half and eliminates the assembly altogether. As companies experience change and turnover in their purchasing groups, they seek to streamline the purchase process and reduce the total number of suppliers they must manage.  The decision to purchase wire welded electrical contacts vs rivets produced in house, eliminates the downtime waiting for components to arrive as well as the cost of shipping, securing and inventorying raw materials including costly precious metals.

Process and Material Cost Reductions

Wire welding uses the same wire as a rivet heading machine, but integrates the attachment and coining of the contact tip right into the stamping of the brass or copper part. This eliminates both the cost of making a rivet and staking it to the part. In many cases, two parts can be made with every stroke of the press to produce more than 600 assemblies per minute!

With the cost of labor, personnel turnover, and employee training to assemble two units together significantly reduced with a wire welded design, the challenges of machine downtime as a result of misfeeds and repair are also eliminated.    The one step process of wire welding eliminates these issues and produces 100% usable parts.


To meet RoHS compliance, many of our customers are working to replace the cadmium specified in a AgCdO rivet with an AgNi wire welded contact.

Checon’s Answer

With 100% usable parts, fewer suppliers, lower shipping costs, less machinery to maintain, lower labor costs, and overall savings due to fewer process steps, no wonder so many of our customers are considering switching from rivets to wire welded electrical contacts.

To find out more about our wire welded solution, call Steve Carter at 508-809-5112, or email him at carter@checon.com.