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splice crimp process

Solderless Crimp Connection

Splice crimping is a solderless electrical connection made by compressing a metal clip around two or more component ends. It works with wire, PCB, coil, capacitor, sensor, diode, lead frame and textile — regardless of size or material. Unlike soldering or welding, it uses no heat, so there’s no burnt or melted components, and the connection quality can be verified both during and after production.

SPLICE CRIMPING BROCHURE PDF

How Splice Crimping Works

  1. Components positioning — components are aligned in the crimping area in the correct order.
  2. Splice band cutting — a metal clip is cut to length from the splice band reel and positioned over the components.
  3. Splicing — the clip is compressed tightly around the components, forming a gastight, solderless connection.

Splice Crimping Advantages

  • Reproducible quality — same tooling, same band, same result, cycle after cycle
  • Gastight — deformation during crimping seals the connection against moisture and corrosion
  • Low electrical resistance — stable contact with noloose strands or misalignment
  • Vibration and deformation resistant — no heat involved, so no melted or burnt components
  • Compact — down to 0.46 × 0.24 mm cross-section, used in cardiac pacemakers
  • Universal — works across component types, materials (fiber, Teflon, chrome, steel) and sizes
  • Quality-controllable — verified inline (Crimp Force Monitor, camera control) or in the lab (pull-force, cross-section, resistance)
  • High throughput — up to 2,000 splices per hour, no operator experience required
  • Cost-efficient — spare parts last 300,000–3,000,000 cycles and cost less than soldering/welding consumables

Where Splice Connections Are Used

Component types: Wire & Wire · Wire & PCB · Wire Coil · Wire Diode · Wire Capacitor · Wire Sensor · Wire Lead Frame · Wire Metal Tab · Wire Plastic Connector · Diode Resistor · PCB Coaxial Connector · Cords Filament

Our Splice Connection Expertise

  1. Splice band definition — material, type, thickness (0.2–0.53 mm) and length selected for the application
  2. Tooling definition — FEA-modeled clincher and punch design, validated against our database of past connections
  3. Connection simulation — FEA modeling of strain and stress to define compression rate, contact resistance and connection dimensions
  4. Laboratory tests — pull-force, electrical resistance, galvanic corrosion and thermal stress testing
  5. Equipment manufacturing — machine built to the validated parameters, at the required automation level and volume
  6. FPC solution — control list, microsection measurement software, and annual connection re-validation

Splice Crimping Equipment - Complete Product Range

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