Connector Durability Testing
At Tektos, we rigorously test every connector system to ensure mechanical integrity and long-term performance across real-world use scenarios.
What We Test
1. Plug–Unplug Lifecycle
We simulate years of use by repeatedly connecting and disconnecting the product using automated cycling rigs.
Up to 10,000+ plug-unplug cycles
Captures fatigue, wear, and insertion/extraction degradation
Tested across USB, Type-C, DC jacks, and custom connectors
2. Insertion & Withdrawal Force
We measure the force required to plug in and pull out each connector to ensure user comfort and standard compliance.
Verified against industry norms (USB-IF, IEC, etc.)
Avoids overly tight or dangerously loose connections
3. Mechanical Retention & Pull Strength
We simulate accidental tugs and stress at different angles to validate connector robustness.
Tensile and retention force tests
Ensures cables stay connected under daily movement
4. Electrical Continuity & Resistance Monitoring
Before, during, and after mechanical testing, we continuously monitor:
Contact resistance (mΩ-level accuracy)
Signal continuity under strain
Performance drift across thousands of cycles
5. Environmental & Long-Term Aging
We combine plug/unplug testing with:
Humidity, temperature, and salt spray exposure
Vibration and thermal shock testing
This ensures your connector remains stable not only mechanically, but electrically, over time.
Why It Matters
Plug–unplug stress is one of the leading causes of field failure in embedded systems and wearables. We design and test every connector to deliver:
Tactile reliability (secure fit, consistent feel)
Signal integrity (no dropouts or resistance spikes)
Long lifespan (sustained performance after years of use)
Tektos Standard for Durability
✔️ Minimum 10,000 plug cycles without failure
✔️ < 30 mΩ resistance shift (typically < 5 mΩ)
✔️ Full compliance with customer spec or better
