Hi Bob; In a prior life, when I used to try to do this in the press fit backplane business, for a pin this size we would specify a finished hole size that was something like .030" +/- .002". In addition, we specified solder plating and reflow for the board, as the solder, being soft and malleable, would lubricate the insertion of the pin through the hole and at the same time, hold it in place until fusing. However, the tighter hole tolerance and the requirement for solder plating (or selective solder) present their own range of disadvantages and problems for the board manufacturer. I would suggest that you try a small quantity first, and get with your pcb manufacturer(s) for capabilities and suggestions prior to doing anything serious. Regards Greg Schroeder [log in to unmask] ______________________________ Reply Separator _________________________________ Subject: assembly - pressfit connections Author: [log in to unmask] at SMTPLINK-HADCO Date: 6/18/96 7:19 PM TechNet Users, We are presently attempting to pressfit a rectangular pin into a through-hole of an .062 inch thick PCB. The dimensions and tolerances of the pin are as follows: Length - .080 inches +/-.002 inches Width - .032 inches +/- .001 inches Depth - .125 inches +/- .002 inches After the insertion process, the pressfit pin is wave soldered into place. Therefore, all that is required of the pressfit pin is that it be retained in the through-hole during normal assembly handling until wave soldering. What should the through-hole dimensions & tolerances be to properly pressfit the pin? Thanks, Bob Mykich [log in to unmask]