A Quick Guide to Proper Wire Crimping Technique

Are you looking to learn about wire crimping? If so, you’ve come to the right place! Our quick guide will show the proper wire crimping technique and offer tips for a strong and stable crimp.

Make Sure You Have the Right Tools

You can often trace wire crimping mistakes back to the preparation and tools of the crimper. Crimping tools have various designs, so it’s easy to get confused and select the wrong tool or crimp terminal for a wire.

It’s wise to consult the OEM manual or website for tooling information. As long as the tool will accept the crimp terminal and has a ratchet design, it should be capable of crimping the wire effectively. You also have the option of an automated wire crimping machine that always uses the correct method for crimping connections.

Stripping the Wire

After gathering the right tools, it’s time to strip the wire for the crimping connection. Strip the end of the wire by cutting off the insulation and exposing the wire strands.

Only crimp wires with individual strands; never crimp a solid wire. The exposed wire should be roughly equal to the length of the barrel, and the stripped wire should fit into the connector with little or no free space. No more than two millimeters of wire should protrude from the connector.

Crimping the Connection

After exposing the wire and placing it in the connector, it’s time to crimp the connection. Ensure the terminal is horizontal, and position the crimping tool perpendicular to the wire. Be sure that all strands are secure in the crimp.

Pro Tip: If it’s your first time using a wire crimping machine, perform test crimps on other wires before doing the real thing.

All that’s left now is applying force—you can’t overdo the crimp with a crimper, so feel free to squeeze the tool as hard as you like. Ensure a sturdy crimp by tugging at the wire; if it feels good, remove the crimp, and inspect the wire. Confirm that the crimp is in the correct position and the insulation is secure. Then, trim any excess wire emerging from the other end of the barrel.

Conclusion

We hope our quick guide to the proper wire crimping technique has been informative and useful. If you’d like to learn more about wire crimping or are interested in investing in a crimping machine, contact our helpful staff at Tri-Star Technologies today!