At Easychips, we often explain that a complete connector system is not just the plastic housing—it's the housing + terminal, working as one integrated interface.

So how exactly do terminals connect cables? Let's break it down.

1) What Is a Terminal in a Cable Connection?

A terminal is a metal contact (usually copper alloy) that attaches to a wire and then locks into a plastic shell/housing, forming a complete connector system.

2) The 3 Most Common Ways Terminals Connect to Cables

In wire harness design, there are three mainstream connection methods engineers will encounter:

A. Crimp Terminals (Most Common)

Crimping is the dominant method used in automotive, industrial, and consumer harnesses.

B. IDC (Insulation Displacement Contact) / Press-Fit

IDC terminals connect wires without stripping insulation. The metal forks “displace” insulation and make contact directly. Easychips classifies IDC press-fit connectors as a major connector structure option.

C. Screw / Spring-Loaded Terminals

These terminals clamp the conductor using a screw or spring force. Easychips also lists screw/spring-loaded terminals as a key category.

3) Key Technical Factors Engineers Should Check

Choosing a terminal is not just about “pin count.” Engineers should confirm these critical parameters:

Wire gauge compatibility (AWG / mm²)

A terminal must match the cable’s conductor range. Easychips terminals cover a wide range of AWG and mm² options across different pitches.

Contact material

Copper alloy / brass / phosphor bronze are commonly used—each affects spring performance and fatigue life.

Plating (Tin / Nickel / Silver, etc.)

Plating impacts corrosion resistance, insertion force, and long-term reliability.

Pitch / connector structure

Different applications require different connector pitches (1.0mm, 2.0mm, 2.54mm, 3.96mm, 5.08mm, etc.), and Easychips provides multiple package/spec options.

4) Terminal + Housing = A Complete Connector System

A common mistake is choosing only the housing first.

Easychips highlights that the plastic shell and terminal combine to form a complete connector system widely used in electronic and electrical applications.

5) How Easychips Supports Cable Connection Projects

At Easychips Precision Technology, we provide:

wire harness connectors (board-to-cable, wire-to-wire, and more)

plastic housings + corresponding terminals as a complete system

Final Thought

A good cable assembly doesn't fail because the wire breaks—it fails because the terminal connection was wrong: incorrect gauge, improper crimp height, weak retention, or unsuitable plating.

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