How do I choose the correct tool to crimp my wire ferrules?

To effectively use wire ferrules, you will want the correct crimping tool. But how do you know which one to choose? In this blog post we will break down AWG ranges, why it’s important when it comes to wire ferrules, and what crimping tools you would want to choose, to get the job done.

Hand-operated crimping tools are commonly used when it comes to crimping a wire ferrule. These tools are designed to compress the metal barrel of the ferrule around the wire, creating a solid connection. Since wires come in different gauges, it’s important to know the different wire ranges that are commonly used.

Crimping Tool AWG Ranges

Hand-operated crimping tools for wire ferrules tend to fall in specific industry standard AWG ranges for crimping smaller AWG ranges, medium AWG ranges, and large AWG ranges. Here are some of the standard ranges for crimping tools you will find on the market:

28 to 10 AWG
24 to 10 AWG
22 to 10 AWG
10 to 6 AWG
10 to 4 AWG
4 to 1 AWG
8 to 1 AWG
1 AWG to 3/0 AWG
4/0 to 300 MCM

When selecting a crimping tool, it’s important to choose one that matches the specific AWG range you will be working with. For example, a tool that covers the range of 24 to 10 AWG will feature separate slots for each size within that range, although some smaller sizes may share a slot. (Check out our other blog post for more information about American Wire Gauge [AWG].)

Example: FD2410N Crimping Tool

A great example of a versatile crimping tool is the FD2410N. This tool utilizes the industry-standard trapezoidal crimping style and includes six crimping slots, accommodating various wire sizes from smallest to largest:

24/22 AWG (0.25mm²/0.50mm²)
20/18 AWG (0.75mm²/1.00mm²)
16 AWG (1.50mm²)
14 AWG (2.50mm²)
12 AWG (4.00mm²)
10 AWG (6.00mm²)

Common Crimping Profiles

Crimping tools come with various profiles to suit different applications. Some of the most common crimping profiles include:

Square
Trapezoidal
Hexagonal
Figure-eight
C-shape

(Check out our Guide to Different Crimping Shapes for more details.)

Most modern crimping tools have ratchet mechanisms that facilitate the crimping process, ensuring consistent pressure and a secure connection. While traditional crimp pliers are still available, they are becoming less common as technology advances.

Knowing and understanding the various AWG ranges and crimping profiles available will help with selecting the right tool for your electrical projects, ensuring safety and effectiveness in your work. Whether you're a professional electrician or a DIY enthusiast, investing in a quality crimping tool can make a significant difference in the quality of your connections.

Check out our large collection of hand-crimping tools for wire ferrules and if you have any questions or need help, feel free to contact us.