Simple optical comparison
According to the board partner, the adapters come from the same manufacturer that NVIDIA uses, but the first picture already shows serious differences to the naked eye. It’s like a hidden object picture, but in electric form. We can see that the contact springs on the left (old adapter) sit much further into the housing than the almost flush contacts of the new, faulty adapter (right in the picture). But there are other differences too, apart from signs of wear and a different mold.
If we look at the side latches, we can see that it is definitely not the same design and it is highly likely that it either comes from a different manufacturer or must be a completely new iteration. The casting quality of the new plug is also very different. But that alone will certainly not be the reason.
It is also very annoying that the PCI SIG specifies the headers in CEM 5.1, but not the connectors with exact dimensions. It seems that everyone can do what they want here and think that it will hold. Only in this case, it really goes wrong. At the very least, it really is a production error and therefore an absolute exception. Just no feedback after such a report is also a kind of feedback.
Here is a symbolig technical drawing for the spring contacts (in this case a crimp variant):
Re-measured: The old, correctly positioned contacts
Let’s get back to the contacts. To do this, I first use the 100x magnification and look at the old 12VHPWR adapter, which looks exactly the same as 10 other adapters. We can see how far the spring contact is offset inwards. We also note the edges and the quality of the tooling and injection molding. Yes, the spring contacts on the newer 12V2x6 connector have been extended slightly, but not as much as in the next picture.
Let’s take a look at the same contact on the problem adapter and see that it sits much further out. At the very beginning, it was still flush on the outside and has obviously shifted slightly backwards in the course of all the plugging attempts, which could also be the reason why the adapter eventually snapped into place after all. At least a little. If you look closely, you will also see the “laser drill holes” that my later material analysis left behind. You can’t do it completely without losses.
That would also clear up the whole thing. But not quite yet, because the contacts were also stuck much tighter and were also bent open quite a bit. There will probably have to be a material analysis.
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