Learn the Fundamentals of Mechatronics!

Making Convenient Connectors for Prototyping - Using Standard Headers

Using convenient connectors during the prototyping stage is key to getting results fast. In these videos, I show you how to make DIY connectors that are strong and very professional looking. I use standard male headers to provide for the hook-up on the breadboard and standard female headers (consisting of a female housing and crimp pins), which is not so DIY, but I use a standard needle nose plyer to do the crimping, so there is a hint of DIY in there.

Making a good male connector sturdy and functional:

The key to a sturdy connector is to provide a mechanical connection and a soldered connection. Yes, mechanics do come into play even in the fine details of electronics. The mechanical connection will allow for more surface area to be soldered to the lead. The lead has very little protrusion, so it is crutial to use this mechanical method. so, how do you create this mechanical connection? Easy, just strip the insulation of a very small gauge wire (I'm using a flat cable in this case), somewhere around 24, 26 or smaller gauge. take the bare portion of this wire and just wrap it around the lead. This is your mechanical connection. Now solder and the connection is permanent. I dare you to separate the wire and lead! It's tough. If you are wondering what a non-mechanical connection would be, just imagine the wire just placed next to the lead and the two soldered together. It might be prettier, but I promise, you will tear your hair out trying to get those two wires together!

Making the Female Connector:

This is actually not a mystery since we are using the standard method (except for the tool used). The parts involved is a small crimp pin (female), a female connector housing (2.54mm or .1 inch pitch - pitch is the distance from one pin to another - measured from the center of the pin). A needle nose plyer is used for the crimping. I prefer to use the professional crimper, but they are expensive and most hobbyists would not have one of these laying around.