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How Our Charging Connectors Are Designed and Manufactured

Last updated Oct 12, 2026

dé develops its charging connector designs. For the 3, 7, 11 and 22 kW versions covered by the supplied manufacturing document, production follows 21 recorded assembly and packaging stages. These stages cover cable preparation, terminal assembly, wire positioning, cable-entry moulding, continuity testing, potting and final inspection.

Develop the connector structure

The connector design determines how the terminals, wires, seals, fixing parts, housing and cable-entry section fit together. Production then follows the specifications and assembly sequence assigned to each connector version.

Mark the connector housing

The connector housing receives its product markings before the internal assembly is completed.

  1. The dé logo is applied by pad printing.
  2. Specified information is added by laser marking.
  3. The position and appearance of the markings are inspected.

Prepare the charging cable

The cable specification is checked against the production order. The cable is then cut, coiled and stripped to the required preparation dimensions.

During this stage, the cable and exposed cores are checked for damage, including damaged insulation and exposed conductor strands.

Charging cable being prepared for connector assembly
The cable is cut, coiled and stripped according to the applicable production specification.

Prepare and crimp the terminals

The required terminals, resistors, diodes and 0.75 mm² silicone wire are prepared according to the production order.

  1. The resistor, diode and silicone wire are assembled where required.
  2. Sealing rings are placed on the designated terminal positions.
  3. The terminals are crimped onto the prepared wires.
  4. The crimp height is measured against the value specified for that terminal.
  5. Heat-shrink tubing is installed at the specified connections.
Terminal components prepared for crimping during connector assembly
Terminal type and crimp dimensions are checked during assembly.

Arrange and secure the wires

The prepared wires are positioned according to the recorded circuit arrangement. The manufacturing document identifies the following circuits:

  • PE
  • N
  • L1
  • L2
  • L3
  • CP
  • PP

The wires are placed into the wire holder. Upper and lower fixing parts are then installed and secured with screws. The exact wire arrangement depends on the connector version being assembled.

Form the cable-entry section

The plastic material used for the cable-entry moulding is dried before production. The SR section is then moulded where the cable enters the connector.

After moulding, the section is inspected for:

  • Shrinkage.
  • Missing material.
  • Excess material.
  • Flash or rough edges.

This inspection checks the condition of the moulded part. It does not by itself establish the finished connector’s waterproof rating or service life.

Test electrical continuity

The assembled cable is checked circuit by circuit. The documented test covers PE, N, L1, L2, L3 and CP where those circuits are present in the applicable configuration.

The operator checks the continuity state and compares the recorded resistance reading with the range specified for that production version. A unit that does not meet the recorded requirement is identified and separated from conforming units.

This is a production continuity check. It should not be interpreted as a statement about vehicle compatibility, charging speed or certification.

Install the seal and apply the potting material

A connector sealing ring is installed in the specified orientation. The housing is then positioned for internal potting.

In the documented process:

  • The two potting components are mixed at a 5:1 ratio.
  • The recorded potting quantity is 15 ml.
  • The connector cover is assembled and secured.
  • The completed assembly remains stationary for 6–8 hours.

These values describe the recorded manufacturing process and are not user-service instructions. The connector should not be opened or repotted as part of normal use.

Clean and inspect the completed connector

After assembly, the connector is cleaned and visually inspected. The inspection covers:

  • Cable scratches, damage and exposed conductor strands.
  • Heat-shrink tubing installation.
  • Connector-face damage or indentation.
  • Terminal openings.
  • Screws and connector closure.
  • Housing shrinkage, marks, scratches and dents.
  • The internal potting position.
  • Printed and laser-marked information.

After the inspection is completed, the connector is placed in a protective bag and packed according to the recorded packaging process.

What the production checks confirm

Production check What is checked
Crimp measurement Whether the measured crimp height meets the specified value for the terminal
Continuity test Whether the applicable circuits are connected and the recorded reading is within the production range
Moulding inspection Whether the cable-entry section has visible moulding defects
Final visual inspection Whether the completed connector has visible assembly, marking or surface defects

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