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The Importance of Using the Right Tooling

As the intricacy of high-performance contacts increases, the importance of optimising performance has made using the right tooling essential. Using the correct tooling protects investments, and prevents customers from jeopardising reliability, safety, and product warranties.

Terminals that have been designed and qualified together with the appropriate application tooling maximise performance and adhere to UL specification. Failure to use the correct crimp tool with high-performance contacts can impact the ability to deliver superior crimp quality and smooth-running operations. However, purchasing the right application tooling solutions can sometimes prove difficult. Subtle differences between products can go unnoticed by the end-user or make it difficult to differentiate between the appropriate tooling.

Recognising the many dangers of mis-using application tooling, from wasted resources to product recalls, Molex has identified that many problems customers face with their tooling solutions occur during set-up; possibly due to the lack of tooling operating expertise. As the products perform precise work, tooling users must follow specific instructions for both start-up and adjustment.

To avoid improper use of application tooling, it is important to verify whether the correct tool is being used. This can be done by reviewing the specification and becoming familiar with all component functionality. Despite the availability of multiple hand tools and applicators, Molex does not actively offer two tools of the same type. The recognisable differences in quality or tool specification enables users to confidently identify which tool is the right one for them. These differences can be things such as UL rating, wire AWG or metric mm², wire insulation thickness range, or terminal series.

Whatever the tooling need, Molex provides technical support on its complete line of production equipment. This includes manual tools, such as manually cycled ratchet hand tools, battery or pneumatic powered tools cycled by the press of a button, or hydraulic tools cycled by the press of a footswitch. These are available in a variety of power levels, and are the most cost-effective option.

Both semi-automatic and fully-automatic termination is available from Molex. Allowing connectors to be brought into the crimp area, semi-automatic termination enables the operator to present the wire to the connector prior to termination. After aligning the wire and connector, the press terminates the connector onto to the wire at the push of a foot pedal. This equipment provides production flexibility and improves output levels in comparison to manual tools.

In contrast, fully-automatic termination on a wire processing machine only requires an operator be present to ensure proper processing and to replenish the wire and terminals. The end-product is usually deposited into a bin and collected by the machine. Fully-automatic equipment improves output levels in comparison to semi-automatic tools and offers more adjustability to hit the target.

The correct Molex application tooling can be chosen by searching using the Molex terminal number on - all suitable tooling is displayed on the lower right hand side. Molex application tooling offers durable and rugged tools for quality results, every time.

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners.


Molex is a leading provider of electronic components and solutions. Our approach to innovation is key to solving complex customer challenges, allowing us not only to create many pioneering electronic solutions, but also build a globally recognized company.