Which connector/wire type should I use?

[coaxialgamer]

Hello.
I'm working on a logic project involving multiple PCBs, communicating together through wires. Most of the planning has already been done, but I have yet to find an adequate and practical way to connect PCBs together. Some of these boards have as much as ~60 wires coming out.
I first considered Dupont wires, but they're simply not practical given the wire count: they're typically alone or connected in groups of up to 8, whereas ideally I'd want bundles of 32 wires. I'd also like some sort of locking mechanism to ensure wires don't just pop out on their own, which Dupont wires simply can't provide.
I've considered using old IDE wires, but used ones are pretty much the only option. In fact, a summary of what I'd like:

- contains multiple wires (16 or 32)
- is reasonably sturdy
- relatively cheap
- can stay put (locking?)

Anyone have any idea of a suitable solution?
Thanks.

[james_s]

There's a nearly ideal solution to this which has been around for decades for just such applications. Ribbon cables with standard 0.1" IDC connectors, mating pin sockets are available in a multitude of types, locking and non locking, shrouded or open, in a variety of standard pin sizes.

[OM222O]

simplest solution would be something like the PCIe connector. it just requires a separate PCB to act as the bus (I'm not sure how cheep you can get one manufactured) and you don't even need any connectors on the PCBs themselves either! just some gold fingers that slot into the PCIe connector on the bus. the PCIe connectors themselves are relatively cheap.

[coaxialgamer]

Thanks. This indeed seems like something that could work. Unfortunately, I'm not very aware of various connector names hence this post

[mariush]

Go on sites like digikey and use the filters to see only connectors with latch or locking mechanism

or go to connector makers and see their catalogues, for example : http://www.jst.com/home21.html
pick a pitch you're comfortable with (let's say 1.5mm, 2mm, 2.54mm) and see what has friction lock, latch, if it's crimp style or press-fit, etc... site above has pictures, schematics etc..

May be worth checking flat flex connectors and ribbons, could be useful.

ps. also kinda stupid and could have reliability issues but for multiples of 8 wires, using RJ45 (ethernet) jacks and cheap patch cords (factory made) could work.

Also consider DB connectors... cheap and dense, but cables could cost more: https://www.digikey.com/short/pztbpj

[james_s]

The 40 pin ribbon cables and connectors that were widely used for IDE/PATA hard drives are still readily available and would work well for this. I use a bench vice to crimp the IDC connectors onto the ribbon.

[Psi]

Yep, if you plan to build/sell the product, even in low volume, you should definitely consider how you will get these cables made.

I highly recommend finding something easy to get off-the-shelf rather than something custom or something you have to crimp yourself.

Only exception is very high quality products that you sell for high cost and don't need to build many.
In that case buying good quality wire and connectors and crimping yourself can be worth it to maintain quality/safety. (etc automotive)

For general purpose stuff JST connectors are quite common and easy to get in cables of various sizes/lengths for a good price.
I think they max out around 12 pos though