Electronics > Projects, Designs, and Technical Stuff
Pin Connectors, Crimpers, decent connections, and the futility of it all...
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LukeW:
From the OP photo, it looks like you’re dealing with those no-name 0.1” “DuPont” generic connectors, in a small-scale lab or hobbyist application. (If not, what is your context/requirements?)

In general, without thousands of dollars for the proper tooling, manual work with needle nose pliers and sometimes a tiny touch of solder is good enough for this context, and broadly applicable across multiple connnector families.

Or buy the generic “DuPont” crimped jumper wires, either without housings or the individual pin housings, and repack them into housings of whatever number of pins you desire with the pinout you want. (Note that if you’re buying 2.54mm black “DuPont” from Samtec or some other name brand, the pins and housings are not interchangeable with “China Generic.)
Neomys Sapiens:
I have several crimpers for this kind of contacts (B-crimp). Those by Weifmueller, Knipex, Klauke etc, which look like the one you have, with somewhat better designed dies, are satisfactory at best. One from Packard Electronics and the 169347-1 from AMP are a bit better, my preference is the GMT-225 from Daniels.

xavier60:
The PA-09 properly crimps the electrical connection on Dupont connectors but I couldn't get it to crimp the insulation wings properly causing the connectors to be difficult to insert into the housing.
The triangle shaped wings need to be formed into a circle, not curled in. Unless I'm missing something, the PA-09 doesn't have a die for doing this.
I made a 1.5mm circular die opening with my Dremel  rotary tool.
The wings need to be pressed parallel first with the plier end of the crimper.
I'm able to make reliable crimps on AWG 28 IDC cable by folding the strand bundle.
Dundarave:
I've had what I consider good success by using the PA-09's 1.6mm die for the "barrel" part of the connector, and the 1.9mm die for the "wings", both used with a carefully-moderated level of force.

I thought it was possibly a better mechanical bond to have the wing tips actually fold into the insulation, as opposed to simply surround it, but perhaps its a question of taste.  I've included a shot of what that looks like.
stj:
automated machines usually pierce the insulation with the folds, i assume that's intentional or they wouldnt do it so cleanly.
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