Bob Beecham | updated January 27, 2021 at 8:38 AM

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Many electrical connections rely on a terminal (bolt-fixed or push-in connector) whose open end is crimped to the bare end of the wire or cable. The terminals, usually referred to as crimping for short, are made of metal, usually wrapped in PVC or nylon. The crimping tool compresses the crimping part to form a firm connection between the terminal and the cable.

Crimping is used for a variety of electrical connections, from push-in plastics in laptops to metal rings connected to car batteries. They are available in a variety of styles and sizes, but all require crimping tools. Most crimping tools are squeezed like pliers, although they are larger and their mechanisms and jaws vary greatly. Each is designed to adapt to a specific range of wiring work.

With a wide variety of products on the market, it is difficult to know which is the best crimping tool for a specific task. Therefore, please use this guide to understand the types available, factors and features to keep in mind when shopping, and why the following are considered the best crimping tools you can buy.

The thickness of the cable (or wire) is usually given in American Wire Gauge (AWG) or simply "gauge". Crimping is also called a terminal, and it needs a corresponding size to connect normally. The thinnest gauge can be about one hundredth of an inch in diameter, although the 18 gauge (0.04 inch) is the thinnest commonly used. In contrast, the largest AWG 4/0 is almost 0.5 inches wide. Larger cable diameters are usually expressed in MCM (short for "thousand circular mils") and can exceed 1.5 inches.

Since each cable size can be connected to a variety of different terminals, no crimping tool can handle all the work. There are three basic types of crimping tools: handheld, hydraulic and hammer.

Hand-held crimping tools are the most common. They are usually very affordable and offer considerable versatility. These crimpers range in size from those designed for high-precision work (which can be easily placed in the palm of your hand) to models over a foot long, providing the leverage required for heavy-duty crimping.

Although many people use simple squeezing actions like ordinary pliers, ratchets are often used to provide consistent, repeatable pressure application. The jaws are different to suit different types and sizes of terminals. To provide greater range, some handheld crimping tools have interchangeable jaw sets. They may also contain wire strippers and/or small bolt cutters, making the tool versatile.

Although mechanized hydraulic crimping tools can be used in production lines, most of these tools are still manually operated. They use an oil-filled cylinder driven by a lever, which greatly increases the output pressure. Hydraulic crimping machines are usually rated according to the force they can apply. This is measured in tons per square inch (ranging from 8 to 16) and highlights the amazing energy they can produce.

Although often used for heavy-duty applications, hydraulic crimping machines can handle medium-sized terminals thanks to interchangeable crimping dies; the special shape of these steel jaws can securely close the crimp. These tools usually come with a range of options-a typical example might range from 8 AWG (0.12 inches) to 0-250 MCM (0.68 inches).

Hydraulic crimping tools are easy to use, but require occasional maintenance. For example, if air enters the cylinder, performance will be reduced, so purge may be required. The oil seal also needs to be replaced regularly.

A hammer crimping tool is a basic low-cost device, usually best for those who only need a crimping tool occasionally. However, it is also a sturdy and compact tool that can adapt to harsh environments and is often found in car shops and other places where heavy crimping is required.

The hammer crimping machine does not use a mold, but is composed of a height-adjustable wedge-shaped indenter located on a sliding bracket with a V-shaped groove at the bottom. The crimped and connected cables are simply placed in this groove. As the name of this crimping machine implies, closing the terminal is a matter of striking the wedge with a hammer. A sledgehammer of 2 to 4 pounds is recommended, but any heavy hammer will work. You can also use a vise to press the plunger to the crimp.

The mechanical actions mentioned should play a role in your choice, but many other factors must also be considered. Read on for detailed information about materials, applications, etc. to help you choose the best crimping tool for your wiring project.

All types of crimping tools are made of steel. Carbon steel is generally considered to have high durability, but this can be a bit misleading. All steels are a mixture of iron and carbon, so the term "carbon steel" can be applied to any of these metals. To increase toughness, look for high carbon steel (a small but important difference) or hardened steel. The latter is particularly suitable for hydraulic and hammer crimping tools because it can withstand high pressure and repeated impacts.

Hand-held crimping tools usually have plastic or rubber grips on the handles to increase comfort. On cheap crimping tools, this can be very thin and easily cracked. Better quality models usually have thicker pads and better ergonomics to provide a safer grip.

DIY and hobby users often try to find a tool for multiple applications. This is completely understandable, because it helps reduce costs, but improper fit or pressure usually leads to failure. For crimping tools, there really is no "one-size-fits-all" solution, so it's usually best for you to be specific.

This is especially true when dealing with professional connectors. Fortunately, it is not difficult to find various alternatives for each application, including a choice from a decent budget and professional tools. Contractors usually buy several different crimping tools, and they find that the efficiency and reliability of having a tool suitable for the job are enough to make up for the additional cost.

Crimping tool product descriptions usually provide good guidance, but if you are not sure which one you need, please do further research. Using the wrong type will result in poor connection and eventually failure.

In factories and other high-productivity situations, use automated machinery. In most General Electric projects, such tools are usually not necessary, but the amount of operation (or frequency of use) is still an important consideration.

For example, auto repair shops often use hammer crimping tools to modify battery cables. If it is only occasionally required once a month, then a cheap tool may provide sufficient performance and good value. If the same task must be performed multiple times a day, hydraulic crimping tools make more sense. They are more expensive, but faster and require less effort.

Likewise, a basic handheld crimping tool may be sufficient for those who use electronic devices as a hobby. Professionals who perform the same type of maintenance every day will choose the ratchet model so that the same pressure is applied every time the crimping. These will also be automatically released, thereby increasing productivity.

Hydraulic and hammer crimpers are heavy-duty tools that can handle the largest wire gauges. The former is limited by the available chip size, while the latter is limited by how much physical force can be applied. The crimp profile—the shape of the crimp before crimping, which varies by connector type—is not important for these tools, because the variety of tools used is limited.

For more general electrical items, such as repairing household appliances or electronic equipment, there are many different configuration files. These include hexagonal, indented, round, B crimp, etc. The profile defines how the crimp is closed around the cable, so choosing the correct type of jaw is essential to provide a safe connection. Most handheld crimping tools will provide a range of cable specifications, and the type of profile they provide should be clear. However, this is not always the case, so it is always a good idea to check the specifications provided by the manufacturer.

There are dozens of different materials and styles of electrical crimp connectors: nylon, PVC, non-insulated, insulated, heat-shrinkable, ring, spade, Faston, Lucar, Shur-Plug-this list is extensive.

Many of these descriptions have little effect on the type of crimping tool used, as they define the type of connection between the two components. However, certain types of crimping tools are more suitable for nylon than PVC. For example, it is important to understand the specifications of the connector to select the appropriate crimping device. Usually, manufacturers make this easy, not only by giving a clear definition, but also by color-coding the jaws so that you can quickly visually identify them.

Although it is a good policy to purchase crimping tools that match the cable size and crimp specifications you use as much as possible, these tools are not without versatility. Even the basic model can handle various cable and connector diameters. Better quality tools can provide interchangeable jaw sets, which gives you the opportunity to handle three to four times the size and possibly different types of connectors.

Stripping is a necessary part of any crimping operation, and some tools are equipped with blades for this. It may also include a cutter for trimming the cable to a certain length. The crimping tool kit can be further expanded by adding a cable tester or the terminal itself.

The criteria detailed above are used to select the following tools, as well as the accuracy and durability of each product.

Busy professionals and enthusiastic amateurs will appreciate the ease of use, repeatable performance and excellent value of this Titan wire crimping tool. It is designed to handle common insulated nylon terminal types with cable diameters from 22 AWG to 10 AWG. Double crimping dies provide additional cable safety. The jaws are color-coded for quick identification and increase productivity.

The ratcheting action provides good control when tightening, and can generate huge force, but the action is very light and the hand will not fatigue quickly. This is due to the ergonomic handle, which contains a useful quick release lever to deal with occasional paper jams.

The Neiko 4-in-1 crimper can clamp, bend, strip and crimp insulated and non-insulated connectors from 20 AWG to 12 AWG. This versatile, affordable device is 7 inches long and fits easily in a toolbox, but it provides enough leverage to apply enough force during crimping.

Durability comes from forged alloy steels that are hammered into shape under pressure while still in a molten metal state, which makes them more popular than cheap wire crimpers that are usually just stamped out of a metal sheet. The cutting edge undergoes heat treatment and CNC machining to keep it sharp for a longer time. The grip may be more comfortable, but this is a small disadvantage for other widely used tools, which have few competitors in terms of money.

This crimping tool from Wirefy is specifically designed to increase productivity when handling ordinary nylon electrical terminals. Color-coded molds allow rapid positioning and crimping, and double jaws create high-strength connections. Lightly press to secure the terminal in place, so the operator does not need to keep a grip. The star wheel sets precise crimping pressure, and the ratchet action can quickly and repeatably apply pressure. Then automatically release the completed crimp.

Wirefy crimping tools can handle sizes from 22 AWG to 10 AWG. The well-cushioned non-slip handle provides a high level of comfort during long hours of work.

Modern automotive circuits require almost no intervention from a mechanic or engineer-mainly to identify faults and replace circuit boards. However, the battery terminals can still be damaged or worn. The TEMCo hammer crimping machine provides an easy-to-use, highly durable solution and a simple, cost-effective method for small batch situations.

There is no need to worry about incorrect mold installation, because the terminals are only placed in the V-shaped jaws. Then use a hammer to strike or use a vise to tighten the crimping plunger. The indenter is designed to accommodate wire sizes from 8 AWG all the way to 4/0 AWG, making the TEMCo hammer lug crimper also suitable for connecting heavy-duty terminals to welding equipment cables.

The challenge when dealing with heavy crimping tasks is to continuously apply enough pressure to achieve reliable clamping. The standard hand-held crimping machine is not strong enough, and the hammer crimping machine is relatively slow. WBHome’s 8-ton hydraulic crimping tool provides impressive power, speed, and repeatability while also being easy to use.

The crimping machine is equipped with a set of eight dies, which can easily insert hardened steel heads and handle sizes from 8 AWG to 4/0 AWG. Squeezing the rubber handle will exert force and will automatically release when the required pressure is reached, and the safety valve can prevent the pressure from being exceeded. There is even a sturdy plastic case for easy storage and transportation.

Iwiss produces a wide range of household and professional cable tools, and is known for reliability and precision manufacturing. This versatile kit includes wire strippers, crimper, four sets of interchangeable jaws, and a screwdriver, which means you don’t need to look around when you want to change the jaws.

Suitable for installing non-insulated and insulated terminals, it can strip and crimp wire sizes from 22 AWG to 10 AWG. The variable ratchet action provides consistent pressure, and the ergonomic handle provides hand comfort. The kit is packed in wear-resistant Oxford cloth bags, with strong comprehensiveness and good overall quality, making it an affordable choice.

Those who are not familiar with crimping tools may still want to learn more about how to buy and use them. Check out the answers to frequently asked questions below.

Crimping securely connects the electrical connector to the associated cable. Types and sizes can vary widely, from those on the computer circuit board to the power supply (the high-voltage cable that powers your home).

This is not a better question; it is about doing things that fit the project. Soldering is mainly used to permanently connect wires, while crimping is common for detachable connections.

The most important consideration is to ensure that the tool can handle the type of terminal you need to connect and the appropriate wire size.

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