crimping

Crimping is a method of joining two components by deforming one or both with a crimping tool. The deformation forms a mechanical interlock and, when used with conductive materials, an electrical connection. A proper crimp requires compatible materials, correct tooling, and precise dimensions to avoid gaps, cracks, or damage to the conductors or fittings.

In electrical work, crimping attaches terminals, splices, or ferrules to wires. The process uses manual, ratchet, hydraulic, or pneumatic crimpers and dies sized for the connector and wire gauge. The crimp height and seating depth determine the integrity of the joint; oversized or undersized crimps can fail under load or vibration.

Crimping is also used for tubing and hose assemblies, where a crimp collar compresses a fitting around a tube to form a seal. Outside of fluid systems, crimping covers fittings for fiber optics, cables, and harnesses, often chosen for speed, reliability, and resistance to loosening under vibration.

Quality control includes visual inspection, pull testing, and measurement of crimp height. Standards from electrical and automotive industries specify acceptable profiles, material compatibility, and environmental performance. Proper tooling, calibration, and compatible connector and conductor materials are essential to prevent corrosion or electrical resistance problems.

Advantages of crimping are speed, repeatability, and vibration resistance with the right tooling. Limitations include the need for correct dies and materials, potential conductor damage from over-crimping, and the requirement to replace tooling when wear or corrosion occurs.