Quality Assurance
Crimp Quality Standards
Industry-standard crimp quality parameters, inspection criteria, and testing methods for precision terminal wire assemblies.
100% Testing
Every assembly undergoes continuity testing before shipment
Microscope Inspection
Fine-pitch crimps inspected at 20x magnification
Statistical Control
SPC monitoring for process consistency and zero defects
Critical Quality Parameters
Crimp Height
Measured from top to bottom of crimped terminal
Pull Test Force
Minimum force required to separate wire from terminal
Crimp Width
Width of crimp barrel after crimping
Insulation Support
Insulation grip integrity
Pull Test Requirements
Minimum pull test forces ensure secure wire-to-terminal connection. Values per IPC/WHMA-A-620 and terminal manufacturer specifications.
| AWG Range | Minimum Force | Typical Force | Test Method |
|---|---|---|---|
| AWG 32-28 | 3N (min) | 5-8N (typical) | Tensile pull at 25-50mm/min |
| AWG 26-24 | 8N (min) | 12-20N (typical) | Tensile pull at 25-50mm/min |
| AWG 22-20 | 20N (min) | 30-45N (typical) | Tensile pull at 25-50mm/min |
| AWG 18-16 | 45N (min) | 60-80N (typical) | Tensile pull at 25-50mm/min |
Visual Inspection Criteria
✓ Acceptable
- ● symmetrical crimp, centered on wire
- ● Brush or cut strands minimal (≤10%)
- ● Insulation gripped without damage
- ● No terminal cracks or deformation
- ● Proper wire insertion depth
- ● Crimp bell closed properly
✗ Defective
- ● Open crimp barrel
- ● Excessive brush or cut strands
- ● Insulation cut or pierced
- ● Terminal bent or cracked
- ● Wire not fully inserted
- ● Wrong terminal size for wire gauge
Industry Standards Reference
IPC/WHMA-A-620
Requirements and Acceptance for Cable and Wire Harness Assemblies
UL 486E
Standard for Safety Wire Connectors
ISO 9001:2015
Quality management system certification
Quality Assurance Guarantee
Every terminal wire assembly is 100% tested for continuity. We provide Certificate of Conformance and full traceability on request.
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