Fuzz Buttons®

Fuzz Buttons® are high performance proprietary trademarked contact pins available ONLY
from Custom Interconnects and manufactured ONLY in the USA
.  
Fuzz Buttons® offer superior value to other contact technologies such as Pogo Pins, Spring
Probes, Hyberboloid contacts or even soldering.  This becomes especially evident when
requirements such as low signal distortion, high frequency, low insertion force, planarity,
shock/vibration resistance, weight and/or extended life come into play.
Fuzz Buttons® are available in a wide variety of diameters and lengths, with diameters ranging
from .010" to .500" and lengths ranging from .020" to as long as .500".   
Most Fuzz Buttons® we manufacture are intended to address fine pitch contact requirements
primarily at the 1mm pitch level, but also can serve applications with as small as a .4mm pitch.  
Fuzz Buttons® can mate to virtually any packaging type used in the market today - including PGA,
BGA, LGA, CGA, QFN and MCM, as well as any custom packaging that a customer may be
employing.  This makes them ideal for use in PCB/PWB interposers, connectors, Test Sockets
and chip packaging.
We also manufacture many large format Fuzz Buttons® that can resemble cylinders, slugs,
discs, doughnuts and washers.  These are typically utilized for specialized EMI Shielding and/or
for compliant high current capable ground pads.  It is also possible to lay small or large Fuzz
Buttons® on their sides individually or in an end-to-end configuration to emulate a compliant
EMI "bead" or to make a long X-axis or Y-axis connection.

History
Fuzz Buttons® were first introduced to the electronics marketplace in 1959 and were mainly
used in grounding applications.  A later example includes their use as static dissipation pads
for IBM computer chassis in the 1980s.  Additional customers and applications began to
emerge as Fuzz Buttons® gained popularity in the marketas a highly flexible interconnect
design solution.  Soon the military sector took notice and began to utilize them in shock-
resistant PCB connectors for missile and satellites.  In the early 1990s, Fuzz Buttons were
miniaturized to address the growing semiconductor test market.  Fuzz Button test sockets were
highly regarded by customers such as Qualcomm, AMD and Texas Instruments, when low
signal distortion was especially important during development testing, but also for the high
mating cycles required for production testing.
Today Fuzz Buttons® still serve the military and commercial markets in many surprising
applications.  You will find them in weaponry, satellites, space probes, aircraft, test floors,
laboratories, radar arrays, antennas, supercomputers, crash test dummies, automotive
production, communications and even packaged inside high-end RF products such as
attenuators and amplifiers.

Making a Fuzz Button®
Fuzz Buttons® are a simple, yet elegant structure - whereby, the signal element and the spring
are one and the same.  There are no other moving parts that can cause failure or degrade
signal integrity, the Fuzz Button® is the direct mating point.
They are manufactured from a long strand of highly specialized very fine wire (often as fine as
human hair) that offers high levels of conductivity, strength and oxidation resistance.  There are
several wire material types available, most are Gold-plated, primarily for the properties of
conductivity and prevention of oxidation.  The most common wire materials used are either a
Gold-plated Beryllium Copper alloy (Au/BeCu) or a Gold-plated Molybdenum (Au/Mo).  While
Au/BeCu offers the lowest signal distortion levels and high mating cycle repeatability, Au/Mo is
utilized commonly also because of its high level of structural stability at temperature extremes.
Fuzz Buttons® are also available in specialty materials, such as Gold-plated Tungsten (Au/W),
Gold-plated Nickel Chromium (Au/NiCr) or non-magnetic Au/BeCu).  These are used in special
cases - such as operating states at extremely high current or temperature (Au/W or Au/NiCr) - or
when magnetic properties are of special concern.
Fuzz Buttons® are fashioned from these wires using a highly-guarded process that forms them
into individual units of certain diameter and length specs.  The manufacturing process causes
the wire to be randomized throughout the Fuzz Button® structure.
This randomization results in some very desirable effects, such as
  • Breaking up of internal induction fields that otherwise would form from a coiled spring
    configuration
  • Reduced signal path length and skin effect levels
  • Increasing the overall structural integrity and strength of the Fuzz Button®
  • Creating multiple points of contact within the Fuzz Button® itself, an internal "redundancy"

Fuzz Button® Specs
Applications: LGA, BGA, PGA, CGA, QFN and more
Pitch Capability: .4mm and above
Compliance/Travel: 15 - 30% of length / 20% nominal
Compression Force: 34 grams
Current Capability: 5 Amps Continuous
Operating Temperature: -60°C to 150°C
Typical Mating Cycles: Fuzz Buttons alone up to 5000 cycles/ with Hardhats up to 500,000 cycles
Frequency Capability: to 40 GHz in natural state, to 100 GHz with design optimization
Cross Talk/Bandwidth: -20dB@10Ghz
Insertion Loss S21: -1dB@26GHz
Return Loss S11: -20dB@10GHz
Inductance: 0.19nH Self / 0.03nH Mutual
Capacitance: 0.16pF Ground / 0.008pF Mutual
Resistance: <10mΩ
Rise/Fall TIme: 50ps / 50ps
Note: Representative values above are for .020" diameter/1mm Pitch, see Technical Data
page for more information on other configurations.

Contact Technology Comparison
Fuzz Buttons® ...Making Connections


Custom Interconnects, LLC
7790 E. Arapahoe Rd, Suite 250
Centennial, CO  80112
Phone: 303.934.6600
Fax: 303.934.6606
Email:
sales@custominterconnects.com
Click here for Fuzz Button Datasheet
For Fuzz Button® Datasheet,
please click on the picture below:
Technology
Areas of Consideration
Pogo Pins
The signal travels on the outside of the structure,
increasing signal path length and distortion. Many
component parts mean more points of potential failure.
Spring Probes
Often an expensive approach.  Commonly a longer
contact height than is optimal.  Have a very complex
structure meaning more potential points of failure.
Hyperboloid / Hypertac / SuperButton /
SuperSpring Contacts
Challenging to assemble into carriers.  Component
wires sometimes separate from body during usage.  
Size is limited to larger pitch/pad configurations.  Not
intended for high mating cycle applications. Long term
reliability may be an issue.
CIN:APSE®
The annealed wire structure often  limits mating
cycles. Only offered in a single material choice which
limits possible applications.  Have just two diameter
choices which limits pitch/pad matching.
Solder
Fragile in harsh environments such as shock,
vibration and high temperatures, prone to cracking.  
Precision placement equipment is very expensive.  
Very difficult to remove for part replacement.  Often not
RoHS compliant due to lead content contamination..
Fuzz Buttons®
Signal travels via shortest path within the Fuzz Button®
structure; diminishing distortion, resistance and
inductance.  Simple single piece architecture means a
more reliable contact.  When used in conjunction with
Hardhats, high mating cycles can be achieved with
little signal degradation.  Always Lead-Free and RoHS.
Small Format Fuzz Buttons®
Applications: PCB Interposers, Device
Interposers, Production Sockets, Test
Sockets, Connectors, RF / Coaxial
Interconnects, compliant grounding/shorting
plates and internal packaging grounds.
Large Format Fuzz Buttons®
Applications: Compliant grounding,
specialized EMI Shielding and as Static
Dissipation Pads.
Fuzz Button® Part Numbering

WW-DDDLLL

WW = Wire Type
DDD = Diameter (in inches)
LLL = Length (in inches)

Wire Types
80 = Au/BeCu (Gold-plated Beryllium Copper)
Most common due to best S-parameters,
lowest resistance values

81 = Au/Mo (Gold-plated Molybdenum)
Excellent dimensional stability

82 = Au/W (Gold-plated Tungsten)
Higher temperature, premium cost, very stiff

83 = Au/NiCr (Gold-plated Nickel Chromium)
High temperature, low resistance, premium cost

Diameters
.010", .015", .020", .025", .030", .038", .045",
.050", .062", .075", .080", .090", .125", .
150",
.170", .200", .280"
For custom diameters, please contact factory

Lengths
Available ranges shown for each diameter
.010" = .040" to .085"
.015" = .040" to .110"
.020" = .0
40" to .200"
.025" = .0
40" to .200"
.030" = .030" to .250"
.038" = .038" to .250"
.045" = .045" to .250"
.050" = .050" to .250"
.062" = .062" to .300"
.075" = .075" to .300"
.080" = .080" to .300"
.090" = .090" to .400"
.125" = .060" to .400"
.150" = .060" to .500"
.170" = .060" to .500"
.200" = .060" to .500"
.280" = .060" to .500"
For custom lengths, please contact factory

Fill Rate
.010" and .015" diameters = 38%
.020" and greater diameters = 25%
For custom fill rate, please contact factory

Tolerances
Diameter +/-5% (exceptions are .010"/.015" dia)
Length +20/-0%
Fill +/-2%
For custom tolerances, please contact factory
Tolerances are measured in the
free/uncompressed state.  What counts most is
AFTER the Fuzz Button® has been compressed
during usage, whereby the amount of material
filling the holes remains very consistent across
the array.  Secondly, Fuzz Buttons® have a large
range of acceptable travel and compliance, they
can solve many stackup tolerance and
board/packaging planarity issues.
80-020055 80-020070 80-062055 80-020040 80-020063 80-020118 80-063063 80-040200 80-020157 80-020200 80-010070 80-010040 80-055055
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80-040051 80-015080 81-020118 81-020200 weiliandk@163.com 18903792044
Floss Pin Luoyang Weilian Fuzz-Button http://www.fuzz-button.com/ fuzz-button.com fuzz-button spring element contact interconnect
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