Electrical connector assembly and method of manufacturing same using an additive manufacturing process

A method of manufacturing an electrical connector, comprising:

• forming an insulator formed from a dielectric material using an additive manufacturing process;
• and
• forming a cavity extending through the insulator using the additive manufacturing process, wherein the cavity includes a first cylindrical section, a second cylindrical section, a third cylindrical section and a fourth cylindrical section, and wherein the second cylindrical section is disposed between the first and third cylindrical sections and has a second diameter smaller than a first diameter of the first cylindrical section, and wherein the third cylindrical section is disposed between the second and fourth cylindrical sections and has a third diameter larger than the second diameter of the second cylindrical section and a fourth diameter of the fourth cylindrical section, and wherein the cavity defines a frustoconical section located between the first cylindrical section and the second cylindrical section;
• inserting an electrical terminal into the first cylindrical section, wherein the electrical terminal having a resilient cantilevered locking tang feature that projects at an acute angle relative to a longitudinal axis and is configured to retain the electrical terminal within the cavity;
• and
• compressing the locking tang feature as the electrical terminal is inserted within the cavity using the frustoconical section so that it may fit through the smaller second cylindrical section.