A Complete Guide to Crimp Tools

Crimp tools are a varied collection of devices used to join materials or components by pressing them together and creating a seal or crimp. One of the most common uses of crimping tools is the attachment of connectors to the end of electrical cables.

Many crimping tools are multi-functional, with compression available alongside bending, cutting, stripping and similar actions. They are designed to work with particular cable, wire or pipe sizes - or gauges – and some models work with several.

There are various types of crimp tool available, each with distinct advantages and disadvantages. For smaller crimping requirements, where precision is key, a manually-operated crimp tool will most likely be sufficient. However, when more power is required, hydraulic and electrical models are also available.

• Handheld - Manually operated crimp tools are typically easily portable and are used for smaller items. Visually, they resemble traditional pliers with clamps that bear a ridge on one side and a notch on the other. Crimping pinches the wire and connector into the notch, compressing them together
• Electrical - Battery operated crimp tools require less effort to apply the required crimping pressure as they bring additional battery power to portable models. Different models of electrical crimping too, are available to meet varying requirements, some with ratchets and ergonomic fittings
• Benchtop - These models are bulkier, higher capacity variations designed to be mounted on workbenches to accomplish more demanding crimping tasks. Some are powered by electric motors and others by hand
• Hydraulic - Hydraulic crimp tools require very little effort to operate, with their compression power supplied by hydraulic fluid. They deliver maximum power for demanding repair, maintenance and industrial applications
• Pneumatic – Compressed air-based tools can bring serious force to crimping applications, delivering power for heavy-duty applications. Similarly, to hydraulic tools, pneumatic models use air pressure for the same purpose, and they are available in both manual and workbench models

Crimp tools can be used for many different applications across a range of industries and environments. Here are some additional types of crimp tool:

Bootlace Crimp Tools

As the name suggests, bootlace crimp tools are specifically designed to work with bootlace ferrules, which require a different form of crimping to standard cabling. Precision must be combined with force to ensure a strong indent crimp.

Most bootlace crimping tools are electrically insulated and feature ratchets to ensure the dies are not released until a firm connection has been made. Also, look for crimpers with ergonomic handles for comfort during use.

Bootlace lugs are ferrules in a bracket or angled design and require crimping tools with a clamping facility compatible with this shape.

Auto Electrical Crimping Tools

Automotive electrical crimping tools are designed to provide sturdy joins for the multiple electrical connectors and cables within car engines. These include non-insulated, pre-insulated, battery and ignition terminals, with different tools available for each, all in standard plier designs.

Mini Crimp Tools

Mini crimp pins are manufactured for use with thinner wiring widths. Close-up precision is required, as well as flexibility within tight operating spaces. Some models feature rotatable flip-top heads, making them ideal for use within very confined areas.

PEX Crimp Tools

PEX (cross-linked polyethylene), is a form of flexible plastic that is increasingly used to make water pipes instead of the traditional copper or steel.

It is considerably easier to install and join lengths of plastic than copper or steel tubing. No welding is required, just specialised PEX crimping tools designed to grip the piping firmly and apply the appropriate pressure. Typically used in conjunction with steel clamps, most such tools are accessible to DIY enthusiasts as well as professionals.

Amp Crimp Tools

Amp connectors are multi-pin devices typically fitted within plastic housing. Specialist amp crimpers apply the precise force required to form a strong connection with suitable cabling.

RJ45 Crimping Tool

The RJ45 crimping tool is a flexible and powerful handheld crimper, compatible with CAT5e, CAT6, CAT6A and CAT7 terminals.

RJ9 Crimp Tool

The RJ9 is a widely used handheld crimp tool fitted with three dies (crimping heads) compatible with the standard connector types RJ45, RJ11 and RJ12. This adaptability means engineers require fewer items in their crimp toolsets when conducting repairs or installations.

Crimp tools come in different shapes and sizes and are used in many settings, but they all have one fundamental use - to create a firm and reliable bond.

Electricians, mechanics and engineers typically make heavy use of crimp tools when installing or replacing cables and wires. These tools allow the wiring heads to be precisely fixed to connectors or terminals, forming an exact electrical union.

Electrical crimps do not use solder, making them mechanically stronger. However, they must still be gas-tight - impermeable to oxygen or moisture, to protect the metals within each circuit from potentially dangerous corrosion. Electricians also use crimp tools to fix ferrite beads to wiring to control the flow of current and prevent electromagnetic interference. Ferrite is a blend of ceramic and iron alloy. Pure ceramic beads also play an important role in electrical insulation.

Crimp connectors are multi-sized metal fittings used to fix lengths of cables and wires to other lengths or components. They serve as electrical terminals - the place at which a particular conducting wire reaches its end.

Crimp connectors are typically fixed over a short length of exposed inner wiring after the insulation has been removed. They are used when occasional detachment may be required, or when soldering would not be appropriate.

Connectors are made from materials malleable enough for compression within crimping tools. They are available in multiple shapes for different uses. Common ones include:

• Ring Connectors – for secure attachments to terminals
• Quick Disconnect Connectors - typically barrel or blade-shaped
• Butt Connectors – for wire splicing
• Spade Connectors – for slide connections into terminals

Professionals apply a variety of crimping techniques, depending on the type of crimp required and the wires or cables involved.

Coaxial cable is a widely used form of insulated wiring, used for signals sensitive to outside interference. The shielding that protects the signal requires a special form of crimping to maintain its integrity.

Here is a step-by-step guide detailing how to crimp coaxial cable:

• Cut the coax with sharp wire cutters, creating a square end but maintaining a cylindrical shape
• Insert the coax into a specialist stripping tool, apply even pressure, and turn the cable carefully
• Remove the coax from the stripping tool and carefully peel away the outer coating of the wire from the cuts made by the stripper, exposing a length of foil
• Carefully peel back the foil to expose the metal mesh within, then bend the metal mesh itself back smoothly over the wire. Be careful not to touch the second layer of foil beneath the mesh
• Insert the coax into a cylindrical F connector without twisting it in the process. The insulation around the central wire within the coax should be pressing against the front flange of the F connector
• Crimp the connection using a suitable coax crimping tool. Apply firm pressure and then release

How to Use Insulated Crimp Terminals

Take a look at our video to learn how to use insulated crimp terminals safely and efficiently. This video provides a useful overview, giving you the basics you need to know in order to operate a crimp terminal.

Alternatively, click the button below to browse our full range of wire terminals and splices.