Introduction

If you are involved in building electronic devices or systems, understanding connectors is crucial, albeit not the most thrilling topic. There is an astounding variety of connectors available today, with major distributors like Digi-key, Farnell, and Mouser offering tens of thousands of products in this category!

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Given the overwhelming number of connector options, selecting the right products can be a daunting task, especially if you're looking for general-purpose connectors or stocking supplies for personal use. This article aims to highlight some common types of connectors and discuss crimping and tooling considerations.

Each connector system typically requires its own specialized crimp tool, often costing more than what most hobbyists are willing to invest. While I do own many official tools, I wouldn’t necessarily recommend them for budget-conscious builders.

Budget-Friendly Tool Recommendations

• IWISS SN-: This four-die tool is perfect for smaller contacts and is well-suited for many medium-sized power connector families such as Microfit, Mini-Fit Jr, E.I., KK .156, Mate-n-Lok, and JST PH. Its well-machined jaw helps avoid jams, enabling efficient crimping of both conductor and insulation concurrently with a reliable ratchet mechanism, though it can apply excessive pressure on the insulation.
• IWISS SN-58B: A larger alternative from IWISS that also features four dies but is recommended for users dealing with bigger contacts.
• Engineer PAD-11: In contrast to the PA-09/21, this tool has precisely machined jaws to facilitate easy contact removal post-crimping, although it is pricier and excels in crimping smaller contacts like PH, XH, and Picoblade types.
• IWISS IWS-M: A more affordable imitation of the Engineer PAD-11, though it lacks the same craftsmanship.

Advanced Options for Additional Budget

Hozan P-707: Frequently recommended by users over the years, I personally found this tool commendable. Generally priced around $70-80, it must be sourced from Japan.

Here are the standout features:

• Exceptional crimping force due to a compound hinge that maximizes pressure, allowing for significant connection strength.
• Two O-shaped crimping dies, a rarity in generic tools, enhancing performance for crimping DuPont connectors.
• The ability to crimp conductor and insulation separately reduces the risk of improper compression.

However, using the Hozan may require more effort than the IWISS tools and can yield less consistent results depending on your grip strength.

Research and test various tools; there are countless generic options available, and it is impossible to evaluate them all.

Specific Tools versus Generic Ones

There are key differences when comparing professional tools with generic ones:

• Single action operation vs. multiple actions needed with generics.
• Correct crimping force achieved consistently with originals versus difficulties with generics, especially with smaller wires.
• Inclusion of a locator in original tools ensures perfect alignment during crimping.
• Original tools minimize insulation penetration, ensuring longevity for mechanically stressed terminations.
• Pricing tends to be significantly higher for original tools, which can span from hundreds to thousands of dollars due to their specialized nature.

Alternatives to Soldering Contacts

Soldering is often viewed as an alternative to crimping. However, it poses mechanical risks as solder may travel up the conductor, exposing it to damage.

Gas-tight crimps are only required in critical applications—where current load and long-term reliability are essential.

Understanding Connector Types

In my early days, I often used no-brand connectors without much thought to their plating quality. Yet, I learned the hard way that using different metal platings can lead to equipment malfunction over time.

For reliable builds, it is wiser to opt for well-known brands with gold-plated contacts. If budget constraints exist, Tin-plated contacts from reputed manufacturers outperform generic options.

Materials Matter: Brass vs. Phosphor Bronze

Phosphor bronze connectors are preferred due to their hardness and longevity compared to brass counterparts, which may require more frequent tension adjustments.

Popular Connector Types

Mini-PV connectors and various common JST connectors are frequently used by hobbyists. For in-depth details on these, separate dedicated pages can provide more information.

Connector Manufacturer Landscape

The connector market is flourishing and currently estimates at around $64 billion globally, with projections to grow substantially.

Some leading manufacturers include:

• TE Connectivity: Established leader in automotive and medical connector manufacturing with a robust global presence.
• Amphenol: Renowned for a diverse range of connectors and a history reaching back nearly a century.
• Molex: Well-known for making some of the most sought-after connectors globally, particularly in the power supply sector.
• Luxshare Precision: Rapidly growing with a wide range of connector products and a strong global market influence.
• April: A pivotal player in automotive and high-voltage applications.

Conclusion

The competitive landscape of connector manufacturing ensures that every manufacturer is continuously innovating and improving quality to meet market demands. For those seeking reliable suppliers, this article serves as a gateway to finding the best China Connector Supplier for your needs. Don't hesitate to reach out if you want more information.