Development of a laser-based microstructuring system for the functionalization of electrical connectors (MESSI)
With the increasing electrification of modern vehicles, the demands placed on electrical connectors are rising rapidly. Electric and hybrid vehicles operate at higher voltages and generate greater operating temperatures, while combustion engines produce strong vibrations due to higher rotational speeds. These stresses lead to increased wear and frictional losses and are considered critical factors that significantly affect the reliability of electronic connector systems. Additionally, the number of required connections continues to grow: modern vehicles contain up to 400 connectors with a total of around 3,000 pins. To ensure these systems function safely and efficiently despite their growing complexity, insertion and withdrawal forces must remain low, as assembly and maintenance are still performed manually. This is precisely where current connector systems reach their limits.
The vision of MESSI is to establish a laser-based manufacturing technology that overcomes these limitations. The Direct Laser Interference Patterning (DLIP) process provides a promising approach by creating defined microstructures on connector surfaces, which increase local contact pressure and specifically improve frictional behavior and electrical conductivity. The project aims to develop a prototype system for the high-precision and cost-efficient production of such laser-functionalized connectors. The technology developed within MESSI forms the basis for a new generation of robust and high-performance connector systems that can be used not only in the automotive sector but also in numerous non-automotive applications such as industrial electronics or high-current charging infrastructure.
Funded by: Federal Ministry for Economic Affairs and Energy (BMWE)
Project partner: SurFunction GmbH
Running time: 12/2025 – 11/2027
Contact:
© Bogdan Voisiat
Mr Fabian René Ränke
Dipl.-Ing.
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