DIFVAN is a professional crimping tool manufacturer and electrical product supplier serving global buyers. We focus on quality, consistency, and long term cooperation.
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Difvan provides a wide range of crimping tool for all kinds of terminals including an insulated terminal, non-insulated terminals, heat shrink terminals, and end caps.
Difvan provides different tool type for cord end terminal and twin cord end terminals including DIFVAN-8-6-4 and DIFVAN-8-6-6.
Difvan Wire crimping tool is very popular during the connection between wire and terminals because it both can crimp and cut, very easy for using.
Difvan YQK-240/ YQK-300 are popular tools for cable lugs with the features of easy to use and different die set can be adjustable.
Difvan ratchet terminal crimping tool has the advantage of labor saving which can increase frication and help you use less effort when crimping.
Difvan Crimping tool set to provide a wide wire range connection for different users, it has matched with the different die set.
Difvan auto crimping machine hlep the wiring harness factories to get a more concrete position during the wire crimp.
Difvan Cable tie tool is a perfect cable tie cutting and fastening tool for all the cable tie buyers. Including nylon cable tie tool and stainless steel cable tie tool.
In making connections with your wires and cables, it is a necessity to choose the correct terminal, wire types and size and connectors to be used. It is also important that you check if it is properly connected. In modern connections, simply attaching a stripped wire is not enough and this is where a Crimping Tool is used for.
Being a Crimping tool manufacturer, let me guide you to select the right tools:
A Crimping Tool is a device that helps in conjoining a metal connector and a wire or cable. It is used to crimp the connector deforming its barrel that secures your wire connection in a tighter grip of the copper wires.
This helps in holding the copper wires and avoids it from fanning when you connect it to a connector or a terminal. It is also a great tool in making sure that your connection will have a 100% contact.
A Crimping Tool is also designed in different types that suits your need in wire connections. It is also available in different sizes that can accommodate the wire size and connectors needed to be crimped.
Other than that, different crimping tool with dies is also available that provides you different die set that corresponds to the cable groups you are using from the 0.25 mm wire gauge onwards.
A crimping tool is not just another hand tool. In electrical and wiring work, it plays a direct role in connection quality and long-term performance. When you terminate a wire into a terminal, connector, or cable lug, crimping creates the physical joint between the conductor and the connector. This joint carries both mechanical load and electrical current. If the connection is weak, loose, or inconsistent, it becomes a point of failure in the system.
Proper crimping replaces soldered or improvised connections. It creates uniform contact between wire strands and the terminal barrel. The result is a connection that resists vibration, minimizes electrical resistance, and lasts longer under load. Using the right tool and method will reduce field failures, callbacks, and maintenance issues.
For professionals who build harnesses, control panels, switchgear, or service electrical systems, understanding crimping tools is essential for quality work. Many failures in field wiring trace back to poor crimps, not poor components.
The following are the types of crimping tool designed for their crimping purpose:
A Ratchet wire crimping is a type of crimping tool that has a built-in ratchet. This feature helps to prevent the crimping tool jaws from opening back as you crimp your lugs or connectors and making crimping easier.
These tools use a ratchet locking mechanism to ensure a complete crimp before the handles can open. The ratchet builds consistent force and prevents under-crimping. This makes them ideal for repeated work where quality and repeatability matter. Ratcheting crimpers also reduce fatigue in medium-volume tasks and help technicians maintain consistent output across many crimps.
After crimping, the ratchet will release its lock when enough pressure was used. This allows you to identify whether you have crimped your connectors well or not.
This is a safer crimping process than your typical pliers which does not guarantee a properly crimped connection. Improper crimping will leave air spaces on your crimped wire that may cause erosion, or loose crimp of wire may cause wiring failures.
Ratchet Wire Crimper
Ratchet Wire Crimpers are designed in different types.
Each wire crimpers varies in what crimping tool you should use based on its terminal types and tells you what proper crimp profile you should use. The following are also what you should consider in choosing the right crimping tool.
a.) Insulated terminal
b) non-insulated terminal
c.) flag terminal crimper
d.) open barrel crimper
In a simple explanation, this figure shows you what crimping profile is required each type of terminal is needed.
Crimp Profiles Reference Chart
It is also important that you learn both the wire gauge and crimp profile of each terminal you will use. This will easily let you know how to crimp your connection and what crimping tool to use.
This will greatly help you produce a safer and long-lasting connection.
The Bootlace Crimper is also known as Ferrule Crimper. This is used in crimping ferrule terminal which is used in control units and switching cabinets that provides a higher contact reliability.
Ferrule crimpers are designed specifically for ferrule terminals used on stranded conductors. Ferrules wrap around wire ends to provide a solid barrel connection. Effective ferrule crimpers produce a uniform circular compression that prevents wire strands from fanning or breaking under load. Ferrule crimps are common on control panel terminations where terminal block reliability is critical.
A Ferrule terminal requires a specialized tool and that is the Bootlace Crimper.
Bootlace Crimper
The crimping process of a ferrule is different from other terminals because it is done by crimping the metal tube than the insulation.It is also designed with one crimping station that can crimp a specific range of wire sizes.
For example, the smallest Bootlace crimper can crimp a wire from 0.25mm² up to 6mm².
The Lug Crimping Tool is a crimping tool that can accommodate different types of lug from electrical and cable lug. It is a crimper that is used to crimp the lug’s barrel.
Lug crimping tools are built for larger cable lugs used in power distribution, battery systems, and heavy electrical connections. These tools cover wide wire ranges and larger terminal sizes. They are designed to deform the lug barrel uniformly. In larger applications, proper lug crimping ensures stable current paths and prevents hotspots that could cause insulation damage or failure.
It can accommodate from 0.25 mm² up to 1000 mm².
Image 3. Ratchet Terminal Crimping Tool
A lug crimper is designed with one crimping terminal that can crimp a range of wire and terminal sizes. Some are also designed with multiple crimping terminals.
It is also important to note that there is a specific type of lugs that require single or multiple series of crimps to have the correct compaction and avoid connection failures.
The Hydraulic Crimping Tool is a crimping tool used for crimping larger types of wires and cables. This is available from yqk 70 up to yqk 300 wire size.
When wire size exceeds what hand tools can manage, hydraulic tools provide the force needed. Manual hydraulic tools use hand-pumped pressure to crimp large lugs. Battery powered hydraulic tools combine mobility with high force, supporting 300mm² and larger conductors used in utility or industrial applications. These tools are essential where cables carry significant current and require secure mechanical and electrical joints
It is a heavy-duty wire crimper that provides connection no matter how big the connections you need to make. A hydraulic crimping tool has a crimping force from 6 tons up to 15 tons
It varies in sizes from:
Hydraulic Crimper Tool
It is also designed in two types for industrial applications:
It is a type of Hydraulic Crimper Tools that is lightweight and easy to use. They usually range in sizes from 22 AWG up to 2 AWG wires and terminals.
This is an example of a Hand hydraulic Crimper Tool that can accommodate up to 300mm² and weighs 7.7kg.
Hand Hydraulic Crimper Tool
This is a type of Hydraulic Crimper tool that is used with utility power cables. This image is an example of a battery powered Hydraulic Crimper Tool that can accommodate up to 300mm².
It is commonly used for crimping cable lugs and weighs 4.0 kg.
Power Hydraulic Crimper Tool
One of the main concerns of Hydraulic Crimper Tools is its weight and crimping capability. Since it accommodates larger sizes of wire, a simple hand pressure grip to crimp the terminals won’t be enough and requires users with more cost and workload.
But, the current design update will ensure to provide you with a lightweight crimping tool that is more durable and allows you to crimp faster.
Crimping tools work by deforming the terminal barrel around the conductor. The crimping dies compress the metal in a specific profile that maximizes contact area without cutting into the conductor strands. Uniform deformation is key. Too little force leaves the conductor loose. Too much force damages strands and raises resistance.
The design of the crimp profile and the matching dies determines how the tool transfers force. Ratcheting tools ensure the full cycle completes before release. Hydraulic tools generate consistent high pressure. Interchangeable die systems allow one tool to serve multiple conductor sizes.
Getting the mechanics right ensures the connection carries current smoothly and resists mechanical forces during operation and maintenance.
A properly crimped terminal is one of the most overlooked parts of the connection process. Some use pliers or improper tools in crimping their terminals because of various excuses.
One of the most common Crimping tool replacement is a plier, vises, hammer, or flat rocks. Even if it is possible to crimp your terminals with these tools, it doesn’t provide you with a proper crimp.
This also doesn’t ensure your wire connection’s durability and contact to power source compatibility. Improper tools for crimping might over crimped your terminals or have a loose connection.
There is a high possibility that due to improper crimping, it won’t guarantee your safety and your product. It may cause electrical failure and wire corrosion that will definitely cost you more for regular replacement and rework.
In order to produce a safe and long-lasting connection, choosing the right terminal and right crimping tool is essential.
In making wire connections which are depending on your needs, multiple Crimping Tools are available for you to buy and use. The following are the things that you need to know about choosing the right crimping tool:
In making electrical connections, it is always important to know what size of wire you are going to use. This is one of the most important parts not just in connecting your wires but also what you need to consider before buying your crimping tool.
A single crimping tool is not designed to universally crimp all types of connectors and each crimping tool can only accommodate a certain range of wire sizes. That is why it is important that you need to know the wire sizes you usually use to properly provide you with the right crimping tool that you need.
Determine the range of conductor sizes you will work with. Tools are rated by mm² or AWG ranges. A tool that can handle your full range of sizes will reduce tool changeovers and errors.
Crimping tools are designed to crimp your wires to a terminal. Each terminal is also designed with various purposes and design.
Different terminals require different crimp profiles. Ring, spade, fork, disconnect, ferrule, and lug terminals each have unique geometries. Match the tool’s die profile to the terminal type to ensure consistent crimps
When buying your crimping tool, don’t forget to take note what terminal you’re going to use.
There are commonly 5 types of terminals:
Each requires a specific crimping profile.
Identifying what terminal you‘re going to use beforehand will definitely help you choose the right crimping tool.
The amount of connection that needs to be done differs from one person to another. Some are just used for house appliances and simple projects or repairs.
Low volume or field service work benefits from handheld crimpers with ergonomic grips. Medium volume work favors ratcheting tools for consistency and ease. High volume or heavy duty work generally requires hydraulic or automatic tooling for speed and reliability.
Others are certified electricians that have their own shops. That is why it is important to consider this because each type of Crimping tool has various designs for the users’ convenience and purpose. There are crimping tools designed to simply crimp your connectors while there are also those who have a 2-in-1 or 3-in-1 feature.
Some crimping tools have multiple crimping terminals or a single terminal.
It is also available as a crimping tool with a cutter or with a wire stripper.
In every product that you are going to buy, the warranty and certification are one of the things you should always check. Some crimping tool needs to use a terminal from the same brand, so it is important to look at the products’ warranty guidelines.
This will ensure you that any defected crimping tool may ensure you that it’s still possible to be replaced and fixed from the producers.
The certification of the quality of the crimping tool should also be checked whether it complies with electrical certification departments like SAE or MIL to ensure your safety as the user and the assurance of quality of the product provided.
In having a successful wire connection, these are the key points that to consider how to crimp your connection:
1.) Know what wire size and terminal you are going to use. This will be your vital information on what type of crimping profile needs to be done and what crimping tool you’re going to use.
Strip the insulation just enough so the conductor reaches the full depth of the terminal barrel. Too much exposed conductor can create a weak point or short. Twisting strands slightly can help them seat better without splaying.
2.) Select the necessary crimping tool to what you need. Dies are color coded or marked by size. Always match the die to the terminal and conductor size. This ensures the correct crimp geometry and contact area.
3.) Strip the wire with the right length. The stripped insulation should be done in moderation to the size of the terminal you are going to use.
4.) Twist the strands of the wire together. This is to make your wire insertions easier to a terminal and avoids fanning of wire strands that cause a connection failure.
5.) Insert the stripped wire to the terminal. Make sure that it is properly connected, and all wire strands are inside the terminal and properly reaching the metal part of the terminal.
6.) Crimp the insulated part of the terminal. Make sure that the terminal is being crimped on the crimping terminal based on its size and crimping profile. Squeeze the crimping tool hard enough to crimp the terminal. It makes a cracking sound to let you know if you are properly crimping the terminal.
7.) Check if the terminal is properly crimped. You can test it by trying to pull the wire and connector apart. If it came to lose it means that it isn’t properly crimped.
Perform a physical pull test on the first few crimps to confirm grip strength. Visual inspection helps identify under crimped or misaligned terminals before installation. Avoid testing with body parts; always use controlled methods.
A Ferrule Crimping tool almost has the same the process to connect the wire and the terminal, but the crimping process of a ferrule terminal is quite different.
Instead of crimping it at the terminal end, the ferrule is crimped at its metal part.It is important to know this to avoid crimping errors.
a.) Do not over the strip.
b.) Do not strapless.
In stripping your wires make sure it’s just enough to the length of the terminal till it reaches the end of the barrel.
Too much stripped insulation
This is an example of what an overly stripped wire looks like.
It is more than what is needed.
Even though this is not necessarily a harmful connection, it still exposes too much of its wire strands.
It is recommended in this situation that wire should be trimmed.
A good length of a stripped wire
The image rather shows a correct way of striping your wire’s insulation.
It is just the right amount needed in by your terminal and will certainly provide you with a better connection.
The Crimping Tool may come in two designs: the die-less crimping tool and a crimping tool with die.
These die crimpers are available as with built-in dies or interchangeable dies. It requires individual sets of dies for each connector/wire size.
It is a tool that makes your construction a little less complicated because it is designed either as with color-coded dies or size identification indent.
Crimping Dies
A Crimping tool with Cutter is designed to cut and crimp wires from 10 up to 22 a.w.g. It is designed for crimping both insulated and non-insulated solderless connectors and terminals.
Its design features help you to crimp on tight places. The advantage of this tool is, it’s easy to carry and handle.
Crimping Tool with Cutter
The Crimping Tool Set is your one-stop best buy from multiple crimping tools. This set may come in as a Ratchet Crimping tool with interchangeable dies that can accommodate different terminals.
Each die is either color-coded or has a size identification indent to easily help you identify which crimping terminal can accommodate a certain wire size. The set also includes a screwdriver and an easy store-away tool bag or toolbox to keep your materials organized and safe.
Crimping Tool Set
The Crimping Tool Jaws is a type of Crimping Tool with interchangeable jaws. Each interchangeable jaw has built-in dies that can be easily removed and connected using a screwdriver.
This enables you to have more option and possibility in crimping different wire sizes and terminal types. It is an adaptable crimping tool that can accommodate your crimping needs.
Crimping Tool Jaws
It varies in types:
These interchangeable jaws may be used to crimp the following:
Crimping tools are used across many professional settings:
Industrial Control Panels
In industrial automation, control panels require reliable terminations. Ferrule crimps on stranded conductors improve terminal block connections, reducing downtime from loose wires.
Power Distribution
Battery banks, transformers, and distribution panels use lug crimps. Hydraulic tools help teams handle heavy gauge cables safely and consistently.
Field Service and Repair
Service technicians rely on portable ratcheting or battery hydraulic tools to complete work on site without access to bench machines.
Harness Assembly Shops
Wiring harness factories benefit from automatic or semi-automatic crimpers. These tools speed up production while maintaining quality standards.
Like all professional tools, crimpers require care:
• Keep dies clean and free of debris.
• Store tools in protective cases to avoid damage.
• Regularly inspect moving parts for wear.
• Replace worn dies to maintain crimp quality.
Well maintained tools last longer and provide consistent performance over many projects.
For businesses with specific requirements, customized solutions are available. Customized crimping dies or tooling kits can be designed to match unique terminal profiles. OEM packaging and branding options help differentiate product offerings in industrial catalogs and tool sets.
In summary, a correct Crimping tool can produce a high-quality crimp and will ensure safety and secure connection.
Crimping tools have several types. To better illustrate, it uses the same general principles as a pair of pliers or scissors. It squeezes a deformable metal sleeve around a wire in order to make a permanent electrical connection.
If you need more information, here pls contact DIFVAN: helen@difvan.com
Tel: 0086-139 8977 1240 (Whatsapp & Wechat Available)
