Manufacturer of contact springs made of copper beryllium as well as EMC gaskets and shielding to customer specification.
ZILLKON Zillgitt GmbH Kontaktfedern
Blankenfelde-MahlowNew on Amplifa
About ZILLKON
ZILLKON Zillgitt GmbH was founded in March 1995 and is a manufacturer of contact springs, special springs, blanks, sleeves, holders as well as EMC gaskets and shielding. Production is mainly from copper beryllium (CuBe2) and other spring materials such as CuNi2Be, CuSn6, CuSn8, CuSn10, CuTiFe, Inconel 718, stainless steel 1.4310, spring band steel and brass. Depending on the quantity, four manufacturing processes are used: etching for prototypes, filigree parts and small series, laser cutting with burr-free cut edges, waterjet cutting without thermal stress, as well as stamping and forming in progressive compound dies for large series. Precipitation hardening under protective gas is carried out in-house, galvanic surface treatments in cooperation with partners. The headquarters in Blankenfelde-Mahlow near Berlin houses production, its own stamping shop and toolmaking; the stamping and bending tools are produced together with the partner company WH Münzprüfer. Annual quantities range from 10 to 10^7 pieces per article. Customer industries include electrical engineering, electronics, medical technology, the automotive industry, aerospace, rail technology, RF technology and military technology.
- Site
- Blankenfelde-Mahlow
- Processes
- Manufacture of contact springs by etching (prototypes, filigree parts, small series), Stamping and forming (stamped-bent parts in progressive compound dies or separate stamping and, Manufacturing on CNC machines, Laser cutting of spring contours from flat material (burr-free cut edge), Waterjet cutting (quality, fine and production cuts, without thermal stress), Hardening / heat treatment (precipitation hardening under protective gas in-house), Galvanic surface treatment (in cooperation with partners), Toolmaking (stamping and bending tools, progressive compound dies, stamping fixtures, injection
- Materials
- Copper beryllium CuBe2 (C17200, 2.1247, Alloy 25), Copper nickel beryllium CuNi2Be (C17510), Copper bronze CuSn6, Copper bronze CuSn8 (C5210HP), Copper bronze CuSn10 (C5240HP), CuTiFe, K55, K75
- Certificates
- DIN EN ISO 9001:2015, ISO 9001, IATF 16949, EN 9100
- Founded
- 1995
- Industries
- Medical technology, Military technology, Automotive industry, Aerospace, Electrical engineering, EMC
- 01
CAD design and material selection
- 02
Toolmaking (stamping and bending tools, progressive compound dies)
- 03
Prototype manufacturing (etching, laser, waterjet cutting)
- 04
Stamping and forming from continuous strip
- 05
Precipitation hardening under protective gas
- 06
Galvanic surface treatment (with partners)
- 07
Assembly, mounting, packaging and labeling
Spring materials and manufacturing processes
Copper beryllium C17200 (2.1247)
Highest strength among copper-base alloys with high conductivity, non-magnetic, usable up to 250 °C.
Copper nickel beryllium C17510
High-conductivity alloy (> 45% IACS) for heat sink modules, resistance welding and electrical applications.
Copper bronze 2.1020
Approved as a spring material per DIN 1654, for connectors, contact pins and stamped-bent parts.
Copper bronze C5210HP
High strength and abrasion resistance for spring contact materials under high mechanical stress.
Copper bronze C5240HP
Engineering material with high elongation at medium hardness.
CuTiFe
High-performance copper alloy for current-carrying contacts with continuous temperatures up to +200 °C.
CuNiSi
High-performance copper alloy for current-carrying contacts at elevated temperatures.
Stainless steel 1.4310
Proven material for EMC contact springs with a broad temperature range.
Inconel 718 (Alloy 718)
Nickel alloy for applications up to 704 °C, hardenable under protective gas.
Monel
Used as knitted wire for EMC gaskets and shielding.
Spring band steel
Sheet material for spring parts under high mechanical stress.
Brass
Conductive material for contacts up to approx. 100 °C service temperature.
Locations
Blankenfelde-Mahlow
DEHeadquarters, production, own stamping shop and toolmaking
- Lot size
- 10 – 10,000,000 pieces/year per article
- Materials
- Copper beryllium, copper alloys, stainless steel, Inconel, spring band steel
- CNC machines
- Progressive compound dies
- Stamping and bending tools
- System for precipitation hardening under protective gas
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of contact springs by etching (prototypes, filigree parts, small series)Joining | – | – | – | – | Copper beryllium, CuBe2, CuNi2Be, CuSn6, Stainless steel 1.4310 |
| Stamping and forming (stamped-bent parts in progressive compound dies or separate stamping andForming | – | – | – | Large series per year | Copper beryllium, CuBe2, CuNi2Be, CuSn6, CuSn8, CuSn10, Spring band steel, Stainless steel |
| Manufacturing on CNC machinesMachining | – | – | – | – | Copper beryllium and other spring materials |
| Laser cutting of spring contours from flat material (burr-free cut edge)Machining | – | – | – | – | Flat spring materials |
| Waterjet cutting (quality, fine and production cuts, without thermal stress)Machining | – | – | – | – | hard and soft materials |
| Hardening / heat treatment (precipitation hardening under protective gas in-house)Heat treatment | – | – | – | – | CuBe grades, CuNi2Be, CuCrSiTi, Inconel alloys |
| Galvanic surface treatment (in cooperation with partners)Surface | – | – | – | – | Copper alloys, Stainless steel, Metals |
| Toolmaking (stamping and bending tools, progressive compound dies, stamping fixtures, injectionEngineering | – | – | – | – | Tool steel, Aluminum |
| Design / CAD design and material selectionEngineering | – | – | – | – | – |
| Assembly of modules (assembly variants: adhesive, plug-in, riveted or screw mounting)Assembly | – | – | – | – | – |
| Manufacture of contact springs, shaped springs, special springs, blanks, sleeves, holdersForming | – | – | – | 10 – 10^7 pieces per year | Copper beryllium, CuBe2, CuNi2Be, CuSn6, CuSn8, CuSn10, CuTiFe, K55, K75, Inconel 718, Stainless steel 1.4310 |
| Manufacture of EMC gaskets and shielding (contact spring strips, profile gaskets,Assembly | – | Lengths to customer specification | – | – | Stainless steel 1.4310, Copper beryllium, Inconel, Monel, silver-plated nylon, tin-plated/copper-coated steel |
| Testing: force-displacement measurement on spring contacts, salt spray fog testTesting | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC machines | – | – | – | – | Blankenfelde-Mahlow |
| Progressive compound dies / stamping and bending tools | – | – | – | – | Blankenfelde-Mahlow |
| 5-axis machining center (partner WH Münzprüfer, toolmaking) | – | – | – | – | Toolmaking partner |
| 3D coordinate measuring machine (measuring lab, partner WH Münzprüfer) | – | – | – | – | Toolmaking partner |
Additional services
Quality
The quality management system is certified by ZDH-ZERT to DIN EN ISO 9001:2015; first article inspection and production are quality-monitored. Testing methods include force-displacement measurements on spring contacts and salt spray fog tests; VDA2-Bemusterung sampling is performed for the automotive industry.
| Evidence | Blankenfelde-Mahlow |
|---|---|
| ISO 9001 | |
| IATF 16949 | |
| EN 9100 |
History
- 1995
Founding of ZILLKON Zillgitt GmbH in March 1995
- 2024
Recertification to DIN EN ISO 9001:2015 by ZDH-ZERT, valid from 21.03.2024 to 20.03.2027
- 2026
Participation in electronica Stuttgart, 10.–13. November 2026, Hall B3, Stand 263