Metal DC Jack Connector 3 Pin — DC-025 Through-Hole Metal Body DC Power Jack for PCB, Adapters & Industrial Power Supply

The DC-025 metal DC jack is a vertical through‑hole DC power connector built with a full nickel‑plated zinc alloy body, providing superior mechanical strength, EMI shielding, and a premium feel compared to standard plastic‑bodied jacks. This metal DC jack connector 3 pin accepts standard 5.5×2.1mm DC plugs and is ideal for power entry on audio amplifiers, industrial controllers, test instruments, and any application where a rugged, panel‑mounted look is desired. The 3‑pin DIP footprint includes center positive, outer shell ground, and a normally‑closed insertion switch that opens when a plug is inserted — enabling automatic battery disconnect or plug‑detection logic.

With a metal body that solders directly to the PCB ground plane via its three through‑hole pins and additional grounding tabs, this connector delivers exceptional pull‑out resistance and low‑impedance grounding. The nickel‑plated finish resists corrosion and wear over 5,000 mating cycles, while the high‑temperature thermoplastic insulator inside the metal shell reliably separates the center pin. For designers seeking a durable, professional‑grade DC input connector that combines classic metal‑jack robustness with modern environmental compliance, this 3 pin metal DC power jack PCB is an excellent choice.

Recommended Footprint

The DC-025 uses a 3‑pin DIP footprint plus two additional grounding tab holes. Pin hole diameters: center pin 2.5mm, outer shell and switch 2.0mm. Grounding tab holes: 1.5mm. Maintain 3mm clearance around the metal body to avoid short circuits. For best grounding, connect the shell tabs and outer shell pin to a solid ground plane.

Wave Soldering

Pre‑heat PCB to 100–120°C for 60 seconds. Solder pot temperature 250–260°C, contact time 3–5 seconds per side. The metal body will absorb heat quickly; ensure the PBT insulator is not exposed to prolonged heat beyond 5 seconds. Allow gradual cooling.

Manual Soldering

Use a 350°C iron with a 2.4mm chisel tip. Solder each terminal for ≤3 seconds. Start with the grounding tabs to anchor the part, then solder the center pin, and finally the outer shell and switch pins. Inspect for solder bridges.

While plastic‑bodied DC jacks are cost‑effective and widely used, a metal DC jack connector 3 pin like the DC-025 offers distinct advantages in demanding applications. The zinc alloy body acts as a built‑in EMI shield, preventing radiated noise from the power supply cable from coupling into sensitive nearby circuits — a common problem in compact audio gear and RF enclosures. Mechanically, the metal body resists the micro‑cracking that can occur in plastic housings after repeated plug insertions, especially in devices where users frequently connect and disconnect the adapter.

The metal construction also provides a more secure panel‑mount feel, as the jack can be directly tightened against an enclosure wall using a nut (if the thread is present), and the body itself contributes to heat dissipation from the contacts. For products that must convey build quality — high‑end audio, test instruments, industrial panels — the metal DC jack adds a premium touch while improving long‑term reliability.

The DC-025 has been tested to guarantee 5,000 mating cycles and withstand harsh environmental conditions. Key test results:

• Mating durability: 5,000 insertion/extraction cycles with a standard 5.5×2.1mm plug. Contact resistance remained below 50 mΩ, no visible wear on nickel finish.
• Vibration test: 10–500 Hz, 1.5mm amplitude, 2 hours per axis per IEC 60068‑2‑6. No momentary contact opening.
• Thermal shock: 50 cycles −30°C to +85°C. Insulator integrity maintained, no loosening of metal‑to‑insulator bond.
• Salt spray: 24 hours 5% NaCl fog. Nickel plating showed no red rust, switch function intact.

For full reports, contact engineering@vistarelectronics.com.

All DC-025 metal DC jack units are packed in anti‑static tubes (100 pieces per tube). The jack is lead‑free and compatible with SAC305 solder. Custom options include different plug diameters (e.g., 5.5×2.5mm), gold plating, and threaded bushing for panel mounting. Standard MOQ is 1,000 pieces. To request a free sample or volume pricing, email sales@vistarelectronics.com with your company details and project application.