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Connector Insights from iCONN

How to Crimp Electrical Connectors

Posted by Rick Regole on Mon , September 2, 2019

Electrical connectors are a type of hardware that affixes to a receptacle to complete an electrical circuit and deliver electricity to a piece of equipment. This connection can be between two wires or a wire to a terminal. Crimping is a process used to join wire to wire or wire to terminal. Just as the name suggests, bonding occurs when one piece of metal is deformed and compressed tightly with another piece of metal. This process does not require any soldering, and involves the following steps and equipment:

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What Causes a Wiring Harness to Go Bad?

Posted by Rick Regole on Mon , August 19, 2019

If a wiring harness fails, causing a short or open circuit, technicians can face a real headache or worse – a full-blown catastrophe. Just imagine if the wiring harness at fault was delivering mission-critical power to a safety sensor or engine. What if the short sparked a fire? In transportation, where thousands of lives are at stake every day, it’s vital to understand what causes a wiring harness to go bad, and how to engineer around risks.

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How Long Does It Take to Install a Wiring Harness

Posted by Rick Regole on Mon , August 5, 2019

Between constant exposure to weather conditions and the relentless rumbling of tires on pavement, the internal workings of a vehicle in the transportation industry can really take a beating. Of course, most vehicle parts are specially designed to stand up to harsh working conditions, but that doesn’t mean they’re invincible.

The electrical wiring inside a vehicle is kind of like a person’s central nervous system. Each wire has a job delivering all types of messages and commands back and forth to different parts of the machine. And just like your nervous system, a single vehicle can contain dozens of miles of wiring that weighs hundreds of pounds.

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The Surprising Benefits of Using a Configurator

Posted by Rick Regole on Mon , July 22, 2019

A connector configurator is an interactive, drag-and-drop tool that gives you the ability to design and customize even the most specialized electrical connectors with just a few clicks. Why should you care? Whether you’re a product developer, manufacturer or supplier, connector configurator technology is going to solve many of your most frustrating pain points. Plus, you don’t need expensive CAD software to access the magic. — just an internet connection.

The configurator software will either guide you piece-by-piece through the design process or — if you’re an expert — will give you the freedom to build without prompts. Technically, users only need to enter three details for the program to crank out a basic compatible design:

  • Number of contacts
  • Required voltage
  • Current strength

After which point, additional parts and features can be altered, added or removed to meet the precise demands of the application.

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What is a Panel Mount Receptacle?

Posted by Rick Regole on Mon , July 8, 2019

What is a panel mount receptacle? The best way to answer is to begin with a breakdown of terms.

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What is Shielding?

Posted by Rick Regole on Mon , June 24, 2019


We live in an increasingly connected world, and despite the advantages of technologies like the Internet of Things (IoT), such innovations don’t come without challenges. For example, globally, there are over 26.66 billion connected devices that send signals back and forth over long distances. All of these device-to-device communications (in addition to other natural and human-made sources) increase the presence of electromagnetic energy all around us. This electromagnetic energy can disrupt the flow of electricity in cables and connectors, resulting in potentially serious problems, such as data loss or total power failure.

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What is Braided Wire?

Posted by Rick Regole on Mon , June 10, 2019

When shopping for the right connector and cable assembly, many seemingly small details about the product will affect performance, reliability and life span. One such feature is braided wire.

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International Protection (IP) Markings: What Do They Mean?

Posted by Rick Regole on Tue , May 28, 2019

Understanding the capabilities of your electrical enclosures or mechanical casings is vital to the success of your product, especially if the application environment will expose your product’s electrical components to harsh elements. However, you can’t always believe the claims made by product marketers. Their definition of “waterproof” may be resistance to splashing while your team’s definition is total submersion. The International Protection Marking (aka “IP Code” or “Ingress Protection”) is a rating system that aims to fix this dilemma.

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What is Overmolding, and Why Is It Important?

Posted by Tony Czyz on Fri , April 5, 2019

What is overmolding?

Simply put, overmolding is an injection molding process in which two or more materials are used to combine the wire and connector to create a single part. To do this, the cable assembly is placed inside a mold. The first material (the substrate) is covered by the other materials in this process. The overmolding process requires a rigid plastic component to be overlaid with a TPU layer or other overmold materials using either the insert molding (a single shot) or multiple-shot molding (two-shot) technique.

Overmolding or overmolded cables are full assemblies that combine the wire and connector into one single, seamless piece. To do this, the cable assembly is placed inside a mold. Next, a molten plastic material is injected into the mold cavity. Once the plastic material cools and solidifies, it conforms to the shape of the mold and encapsulates the junction point between the connector and wire.

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Why Choose a Cellular Manufacturing Partner for Product Development

Posted by Rick Regole on Mon , April 1, 2019

When looking for a manufacturer to continue producing your OEM products, not just any partner will do. Several critical factors will directly impact your bottom line for better or worse, depending on which manufacturer you choose. Among these factors is the type of internal production model a manufacturer uses to process orders. The answer you’re looking for is cellular manufacturing. Here’s why:

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