Connectors and crimping tools. I just want to be "more standard"

[Moriambar]

Hey.

I know this message will upset some because "there's no such things as best for all" and such, but please try to understand what I am asking.

During my long ongoing beginner stage, I frequently found myself in need of connecting things. Apart from ribbon cables, I usually use some thin stranded cable, which I crimp with the "proper" connectors at the end, as I think is standard.

Now, this has started for me way back when I was even more a beginner, so I basically used these kits:
- JST-XH (bought on amazon https://goo.gl/zmdCV6) for pcb/soldered connections
- Dupont (bought on amazon https://goo.gl/VZuSWT) for breadboard and other things

while to crimp I use
- PA-09 (https://goo.gl/K69SaB) for the JST
- the Pa-09 and another beast (https://goo.gl/oDytBq) for the dupont

Since I'm running out of stack of the jst-xh 2 pin connectors, I thought of asking here whether those are the "best" choice I can have and also how can I find them (I do not think they're particularly used, so it was difficult to find the 2pin one at an affordable price in nice quantites). Please bear in mind that I do rarely need more than 100mA and a 1A capable cable/connector is more than enough.

So do you think I have better alternatives (which perhaps are more readily found in other places than amazon) than the jst-xh (which was kinda painful to design pcb around too because many times the component was wrong)? If so what do you suggest? Do I need a different crimping tool?

About crimping tools: crimping the Dupont connectors is really really painful with the tools I have, do you have any recommendations (that won't make me go broke?)

If you read all of this, well thanks a lot, I appreciate that.

I hope this all makes sense.
Cheers

[alex-sh]

Hey.

I know this message will upset some because "there's no such things as best for all" and such, but please try to understand what I am asking.

During my long ongoing beginner stage, I frequently found myself in need of connecting things. Apart from ribbon cables, I usually use some thin stranded cable, which I crimp with the "proper" connectors at the end, as I think is standard.

Now, this has started for me way back when I was even more a beginner, so I basically used these kits:
- JST-XH (bought on amazon https://goo.gl/zmdCV6) for pcb/soldered connections
- Dupont (bought on amazon https://goo.gl/VZuSWT) for breadboard and other things

while to crimp I use
- PA-09 (https://goo.gl/K69SaB) for the JST
- the Pa-09 and another beast (https://goo.gl/oDytBq) for the dupont

Since I'm running out of stack of the jst-xh 2 pin connectors, I thought of asking here whether those are the "best" choice I can have and also how can I find them (I do not think they're particularly used, so it was difficult to find the 2pin one at an affordable price in nice quantites). Please bear in mind that I do rarely need more than 100mA and a 1A capable cable/connector is more than enough.

So do you think I have better alternatives (which perhaps are more readily found in other places than amazon) than the jst-xh (which was kinda painful to design pcb around too because many times the component was wrong)? If so what do you suggest? Do I need a different crimping tool?

About crimping tools: crimping the Dupont connectors is really really painful with the tools I have, do you have any recommendations (that won't make me go broke?)

If you read all of this, well thanks a lot, I appreciate that.

I hope this all makes sense.
Cheers

The answer is it depends.
You did not give any details - what PCBs, space on your PCB, etc.
Are you happy with 2.54mm JST?

I would start from the following. Find out how much space you have and what it is you need, i.e. how many wires you have to connect.
Your search should start here:

https://www.digikey.co.uk/products/en/connectors-interconnects/rectangular-connectors-headers-male-pins/314?k=JST

For me personally, it does not matter - what to crimp or how to crimp it. The question is what it is you want to achieve and how?
Very often there are space or design limitations. And you do not start building a car by choosing wheels first.   

[Moriambar]

The answer is it depends.
You did not give any details - what PCBs, space on your PCB, etc.
Are you happy with 2.54mm JST?

I would start from the following. Find out how much space you have and what it is you need, i.e. how many wires you have to connect.
Your search should start here:

https://www.digikey.co.uk/products/en/connectors-interconnects/rectangular-connectors-headers-male-pins/314?k=JST

For me personally, it does not matter - what to crimp or how to crimp it. The question is what it is you want to achieve and how?
Very often there are space or design limitations. And you do not start building a car by choosing wheels first.   

Hi. I'm kinda happy with the JST 2.54 mm; I just wanted to know what the options are and how to choose. I'm thinking about "general purpose" (or jellybean if you wish: is there a 2n7000 or 2n3904 of connectors?) ones with the loose requirement that it can carry 1A.

I have no space problems or anything like that.

Also crimping tools, in my experience, are a pain: perhaps I've got the wrong ones.

As per your "what do I want to achieve" -> I want to be able to connect my boards! Mostly I use up to 4 wires (if more I use a ribbon) how? In an efficient way (meaning affordable, with standard connectors easy to find and crimp).

But thank you for your link and answer.

Cheers

[mariush]

You could look at what's stocked in the biggest quantities at various distributors.

For example, for board headers,

JST PH ,2mm pitch , 430k in stock : https://www.digikey.com/product-detail/en/jst-sales-america-inc/B2B-PH-K-S-LF-SN/455-1704-ND/926611
JST PA , 2mm pitch , 340k in stock : https://www.digikey.com/product-detail/en/jst-sales-america-inc/B02B-PASK-1-LF-SN/455-1832-ND/926738

JST XH 2.5mm pitch is also in 300k+ quantities : https://www.digikey.com/product-detail/en/jst-sales-america-inc/B2B-XH-A-LF-SN/455-2247-ND/1651045

You also have Molex micro-fit  with 3mm pitch  , te micro mate-n-lok etc

[graeme.c.payne]

First, I have no opinion on the actual connectors - that is a design decision for you.

For the crimping tool, though, I do have a suggestion based on experience in military and the aerospace industry.

Always use a ratcheting type crimping tool. This will always give you a more REPEATABLE connection, and a connection that is STRONGER  mechanically. 

I know ratcheting crimping tools can be painful to use. My solution for that has always been to place the fixed handle on the work surface and press down on the moving handle, using body weight to help as needed.

In the places I have worked, the use of ratcheting crimping tools is required. Non-ratcheting ones were not allowed in work areas.

In some places the tools have also required periodic examination and verification, to be sure that the crimp meets mechanical strength requirements. But that is not needed at the hobbyist level. I use a moderate pull on the wire to be sure it is secure.



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[Domagoj T]

Recently I received a few items:

https://www.ebay.com/itm/Crimping-Tool-for-Hobby-2-0-PH-2-5-XH-JST-Servo-Connector-plug-ETETCR001-/123636534812?oid=113515569625
This one I like a lot. It is easy to use and crimps firmly on both wire and insulation. I did about 100 connections in the last week and had no issues.
I used these connectors:
https://www.ebay.com/itm/50X-JST-XH-Kit-2p-3p-4p-5-Pin-2-54mm-Terminal-Housing-PCB-Header-Wire-Connectors/192266969595?ssPageName=STRK%3AMEBIDX%3AIT&var=492197246956&_trksid=p2057872.m2749.l2649
The connectors are fairly strong and difficult to decouple.

I also bought these, thinking they would be good for stripping:
https://www.ebay.com/itm/Multifunctional-Handle-Tool-Cable-Wire-Stripper-Stripping-Cutting-Pliers-Cutter/172878431868?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649
They are decent, but I work mostly with thinner wires, so they're not ideal for my work. They work well on thicker ones.

Another crimping tool, for ferrules I got:
https://www.ebay.com/itm/Crimp-Tool-Kit-Ferrule-Crimper-Plier-Wire-Stripper-800-Connector-Wire-Terminal/401347433266?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649
They are actually very good, if you work with one wire thickness. Crimping action doesn't require much force but results in good crimp. The problem with them is when you want to crimp different wire thicknesses. They are adjustable and have good range, but to adjust them you need to completely unscrew one fastener and remove it, rotate one plate and replace the screw. That is fiddly and slow.
If you set them for thicker wire than you are crimping, they won't squeeze tight enough. If you set them too tight, you can't properly complete the action.
If you decide to get these I would recommend getting two.

[tkamiya]

I think in metric but for connectors, I avoid anything that is not inch based.  Selections are less, availability are less, and tools are harder to come by, especially in US.

Almost all of my crimp tools for electronics uses are kind Amazon sells.  Just be ready to return if one is not to your liking.  For high current work, I have certified crimpers.  If companies like Amp or Molex sold their tools for reasonable prices, I'd of course go for them.  But near thousand or more is simply not a possibility for me. 

Back when I worked in the industry, all crimp tools were brand specific and the right stuff.  But over $2000 to just attach a small RF connectors?  Not in my own shop.

[Nusa]

Re: dupont connectors. While I am equipped to crimp my own, often I don't need to.

I've a collection of those premade 40-pin ribbon cables with dupont connectors attached at both ends in 20 and 30 cm lengths and various genders (M-M, M-F, F-F). When I need the odd cable I can just strip off the number of conductors I need and snap them into the right size header. If I only need the connector on one end of the cable, just cut off the other end where needed.

[rdl]

Making crimped connectors is tedious and fiddly, but if you have to have individual wires then crimping is usually necessary. Whenever possible try to use IDC connectors on ribbon cable with header pins on the board. It's much easier and quicker.