The new mechanical contacts seem to work fine but need a bit of time invested in repeatability for manufacturing…
The gap between the parallel bars needs to be 0.5-0.6mm to ensure a tight, but not too tight grip onto the LED insert part.
Fortunately, unlike the previous U shaped inserts, the gap is adjustable , either by jamming a flat blade screwdriver in to widen, or using pliers to narrow so at the end of the day, as long as soldering them in is consistent, I can quickly adjust the gap per insert, per board at shipment stage.
Though, with 150 boards planned and 8 gaps to be adjusted, I’d rather get it right at soldering stage- which will likely need a jig of some type.
Another thing I can adjust is the hole in the PCB, manufacturer recommends 0.8mm for the 0.7mm jumper, I could do 0.75mm for a tighter fit which is fine for hand manufacture
Finally, the first alpha test has been successful and the internal i2c is working in the Next! That’ll be for another post, but I now need another Beta board as I’ll need to add an i2c eeprom onboard 🙂