Test Sockets

Tooltronics designs and manufactures custom test sockets and burn-in sockets for power electronics, relays, and semiconductor devices. With decades of experience, we have engineered precision sockets used in demanding test environments where electrical performance, durability, and reliability are critical.

The examples shown in this section represent only a small portion of the many custom test sockets we have designed and manufactured. Because each application can have unique electrical, mechanical, and thermal requirements, many Tooltronics sockets are designed specifically for the customer’s device and test environment.

Our engineering experience allows us to develop high-reliability sockets for power modules, relays, and a wide variety of semiconductor packages, providing dependable electrical contact, accurate pin alignment, and long service life.

Test & Burn-In Sockets for Power Modules and Relays

Tooltronics has extensive experience designing test and burn-in sockets for through-hole power modules and relays used in production testing, reliability testing, and engineering evaluation.

A typical power relay test socket is manufactured from glass-filled PTFE (Teflon) and populated with our LPK-100 and/or LPK-125 Kelvin contacts. Optional materials and contact styles are also available depending on the requirements of the application. Our designs support both straight-pin relays and hook-pin relays, with precise contact orientation to ensure reliable electrical connection.

Power Module LIF Test Socket Design Options

Tooltronics power module Low Insertion Force (LIF) test sockets are available in several configurations to accommodate different device footprints, current requirements, and test conditions.

Standard Socket Materials

Common materials used in our socket construction include:

• Radel 5500
• Ultem 2300

Optional materials include:

• Semitron 225 (ESD compliant)
• Semitron 520HR

These materials provide excellent mechanical strength, thermal stability, and electrical insulation properties required for demanding test applications.

Kelvin Contact Options

Sockets are typically populated with LPK-100 and/or LPK-125 Kelvin contacts for module pin locations requiring 15 amps or less.

For applications requiring higher current capability, Tooltronics offers the HPK series high-current Kelvin contacts. These contacts are designed for specific module pin sizes and are available for:

• 0.025" square or rectangular pins
• 0.040" diameter pins
• 0.062" diameter pins
• 0.080" diameter pins
• 0.150" diameter pins
• 0.180" diameter pins

Each contact pair is rated at 50 amps continuous per side.

For extremely high-current applications, sockets can be designed with three Kelvin contacts per module pin, significantly increasing the available current capacity beyond the standard amp rating.

Zero Insertion Force (ZIF) and Ejection Features

Tooltronics can also design Zero Insertion Force (ZIF) test sockets for many module footprints. These sockets are populated with our HPK-FS series 50-amp Kelvin contacts, allowing high current testing while minimizing insertion force during device loading.

Many sockets can also include a lever-actuated module ejection feature, which helps prevent bent pins and allows safe, controlled removal of the device after testing.

Test Sockets for Semiconductor Packages

In addition to relay and power module sockets, Tooltronics also designs and manufactures custom test sockets for a variety of semiconductor package types, including:

• TO packages (Transistor Outline)
• SIP packages (Single Inline Package)
• DIP packages (Dual Inline Package)

These sockets can be configured for engineering evaluation, production testing, or burn-in applications, and are designed to ensure precise alignment, dependable electrical contact, and long operational life.

Custom Test Socket Design & Manufacturing

Every Tooltronics socket is designed with the goal of delivering repeatable electrical performance and mechanical reliability. Our in-house design and manufacturing capabilities allow us to create custom test socket solutions tailored to the specific needs of each customer.

Applications include:

• Power electronics testing
• Relay testing
• Semiconductor device testing
• Burn-in testing
• Engineering and reliability evaluation

If you have a new device or application requiring a custom test socket, our team would be glad to review your requirements and develop a solution.