Mike, Usually bent pins indicate that the hole is sized too small. Since PWB manufacturers monitor the plating thickness by the smallest hole, you may be getting additional plating in the press fit holes. This small amount of additional plating may cause the hole to be sufficiently small enough to bend the pins at insertion. Also, check your hole size. The corners of teh pins are designed to just touch the laminate material, not dig into it. The copper displaced, forms the gas tight connection. If you are sizing the hole to cut into the laminate material, than you are certainly sizing it to cut into the copper at the flat of the pin. Regards, Gary Ferrari Tech Circuits