How much current are you trying to get in and out of these things? Which is the DUT, the wire harness or the PCB? Guess it's the PCB if current is a concern, since you wouldn't need a ton of current for most harness testing purposes?
Conventional solution to pogo pin pressure is to use a mechanical clamp system, like a cam-like style of thing that has high mechanical advantage to make opening and closing easy. Potentially many other solutions--maybe even just some big heavy alligator clips that can clip onto the terminal?
DUT is PCBA with the press fit terminals on it. To test it I have to connect the motors to the PCB with thick ring terminal wires.
The power also comes in on other terminals as well. So 5 terminals total (motors have a common).
It peaks up to 180A when starting and when I test the motor overload trip, but usually during test it's around/under 40A.
I found some much cheaper INGUN (clone/copy) pogo's on aliexpress that i'm going to do some testing with, see how well it works.
If it seems to work ok or borderline with the clone pogos i'll order some genuine ones.
Just don't want to fork out $400 for 100 pogos and receptacles unless it's going to work.
Was thinking of using an array of 4x4 of these 16Amp ones per press-fit PCB terminal.
They would fit offset into the gaps between the 5x5 press fit PCB holes.
However the force required to get that many to their recommend working stroke scares me.
There is also the risk that the current will heat the springs up and they will lose their springiness.
But given that the 180A is only for a short time, might be able to get away with using less of them
16A pogo
https://ingun.com/en-GB/HSS-100-306-150-A-2000/HSS-100-0006?fbclid=IwAR38iOb58KjU8AwWl8MI8eeTEnOA2agJyUq0LKrHyRx1ZG6O90Q80uNYsfsThis is the kind of terminal
https://www.digikey.co.nz/en/products/detail/w%C3%BCrth-elektronik/7461098/2092196