WiretoWire

Wire-to-wire refers to a class of electrical connectors designed to join two cable assemblies directly, without an intermediate printed circuit board. Also described as wire-to-wire or two-harness connections, these interfaces mate two harnessed cables to create a continuous electrical path. They are chosen when space constraints, accessibility, or modularity favor connecting directly between two wires rather than through a board.

Construction and operation typically involve two mating halves, each terminating a wire or cable end with a crimped or soldered contact inside a polymer housing. The contacts are designed to engage securely when the halves are joined, often featuring polarization keys, latches, or seals to ensure correct orientation and environmental protection. Terminations are commonly crimped or soldered, with some variants using overmolding, heat staking, or integrated strain relief to improve durability in rugged conditions.

Applications span automotive wiring harnesses, aerospace and defense systems, industrial automation, and consumer electronics where two cable assemblies must be connected without a PCB intermediary. They are valued for enabling compact, removable, or serviceable connections and for offering features such as vibration resistance, weather sealing, and EMI shielding in appropriate designs.

Design considerations include current rating and voltage, environmental exposure, mechanical robustness under vibration, temperature range, and mating cycle life. Material choices typically involve copper alloy contacts with tin or nickel plating and housings made from glass-reinforced polymers or other resilient plastics. Connector families in this category are produced by multiple manufacturers and vary in size, pitch, and sealing options to suit specific industry standards and performance requirements.