So I've been doing a bunch of experimenting with the testers, trying to balance manufacture time with my desired price point, while maintaining craftmanship and aesthetics... ha, what a mouthful.
With my last prototype (which I am still using for testing) I've discovered that using one brass screw to hold the bronze prongs in place is not durable enough. If you apply a rotational force on the prong, in a counter-clockwise direction, you could loosen the machine screw. Since I want to remove the screwdriver slots from the screws, any amount of loosening has to be avoided.
For this tester model, I decided to solder the prongs into place, I used low temperature silver solder (lead free, of course). The problem with this solution is that low temp solder has a melting point of about 430F. That's a bit too close for comfort. Higher temp silver solder would be nearing the annealing temperature of the phosphor bronze springs... and once that temperature is hit, the springs will not longer be springy! Also, soldering this many prongs into place will be time consuming. So, I won't be using solder on the final design.
Here is what the metal tip looks like after it's been soldered, cleaned, and very mildly etched and patina'd with vinegar. The patina at this stage is very thin, with almost no rust buildup. But I find it interesting, so I'll probably keep it like this since I'll be keeping it
The final design will use two brass screws on each prong to eliminate any loosening issues. One brass crew will be large, like the ones you see pictured here, and the second will be small, about half the size, since it is acting more like a pin to keep the prong from rotating. This should be durable enough for a lifetime of use, and in the rare case that one of the prongs was faulty and broke, it can be easily replaced.
If it seems that I am slow on getting those testers out there, It's only because I've been trying my best to come up with a design that is perfect.
@Stu , Yep, Agreed!