| 1 | Housing Material | - Polyamide or other engineering thermoplastics
- Polyester-based thermoplastics
- Metal or metal-reinforced housings
| Use an insulating thermoplastic housing for most indoor electrical assemblies. Consider a reinforced or metal housing where higher mechanical strength, heat resistance, or shielding is required. | Check operating temperature, flammability rating, chemical exposure, impact resistance, and insulation requirements before finalizing the housing. |
| 2 | Number of Circuits | - Single-circuit connection
- Two to six circuits
- Higher-density multi-circuit layouts
| Select the smallest circuit count that accommodates the required power, signal, and spare positions. A modular or multi-position housing can reduce wiring space and assembly time. | Allow additional space for creepage, clearance, wire routing, and future circuit expansion. Do not exceed the connector’s approved pole configuration. |
| 3 | Pitch and Contact Spacing | - Fine pitch for compact assemblies
- Standard pitch for general wiring
- Wide pitch for higher current or larger conductors
| Choose a fine pitch when PCB or enclosure space is limited. Select a wider pitch when larger wire sizes, higher current, better heat dissipation, or easier manual assembly are needed. | Smaller spacing generally requires greater control of insulation stripping, insertion accuracy, creepage, and clearance. Confirm compatibility with the mating half. |
| 4 | Termination Method | - Crimp termination
- Solder termination
- Quick-connect or tab termination
- PCB solder-tail termination
| Use crimp contacts for repeatable wire harness production and vibration-prone applications. Use solder termination for low-volume assemblies or applications where soldering equipment is already available. Use PCB tails for direct board mounting. | Verify conductor cross-section, insulation diameter, contact plating, tooling requirements, pull-out strength, and the approved termination procedure. |
| 5 | Mounting Style | - Free-hanging or cable-to-cable
- Panel mount
- PCB mount
- Snap-in or clip-in mount
- Screw-secured mount
| Choose free-hanging connectors for harness-to-harness connections. Select panel mounting for equipment interfaces, PCB mounting for board-level connections, and locking hardware when vibration or repeated service is expected. | Check panel cutout dimensions, PCB hole pattern, retention force, mounting orientation, cable strain relief, and available installation clearance. |
| 6 | Electrical Rating | - Low-current signal circuits
- General control and power circuits
- Higher-current circuits with larger contacts
| Choose contacts whose rated voltage and current exceed the actual continuous load. For mixed circuits, separate high-current and signal contacts where the connector system permits it. | Ratings depend on contact size, wire size, ambient temperature, number of energized positions, and derating conditions. Use the applicable product specification rather than relying only on nominal values. |
| 7 | Retention, Polarization, and Environment | - Friction retention
- Positive locking latch
- Keyed or polarized housing
- Sealed or protected configuration
| Use a keyed, polarized, and positively locking design where incorrect mating, accidental disconnection, vibration, dust, or moisture could affect system reliability. | Evaluate ingress protection, sealing method, temperature cycling, vibration, shock, mating-cycle life, and the need for secondary locks or strain relief. |
