Connectors are the interface points of every wire harness, and selecting the right connector family for a given application is just as important as choosing the correct wire gauge or insulation type. The connector determines how reliably the harness mates with its counterpart, how easily it can be serviced in the field, and how well it withstands the mechanical and environmental stresses of its operating environment. This guide covers the major connector types and manufacturers encountered in professional wire harness manufacturing.
Major Connector Manufacturers
Molex is one of the largest connector manufacturers globally, offering an extensive portfolio from micro-pitch board-to-wire connectors to heavy-duty power connectors. Their Micro-Fit, Mini-Fit Jr., and KK series are staples in consumer electronics, appliances, and automotive applications. Molex connectors are known for reliable terminal retention and broad availability.
JST (Japan Solderless Terminals) specializes in compact, lightweight connectors widely used in battery packs, LED lighting, consumer electronics, and small appliances. Their PH, XH, VH, and SM series are among the most commonly specified connectors for low-to-medium current applications. If you encounter unfamiliar connector series names, our wire harness glossary can help clarify industry terminology.
TE Connectivity (formerly Tyco Electronics) serves virtually every industry with connector solutions ranging from automotive-grade MATE-N-LOK and AMP Superseal series to industrial heavy-duty connectors and high-speed data connectors. Their automotive division produces the ubiquitous AMP Timer, Junior Power Timer, and MCP connector families found in vehicles worldwide.
Amphenol is a leader in circular connectors for military, aerospace, and industrial applications. Their MIL-spec circular connectors, as well as the Amphe-PD series for high-power distribution, are trusted in demanding environments where reliability under vibration, moisture, and temperature extremes is non-negotiable.
Harting is best known for rectangular industrial connectors—particularly the Han series, which has become an industry standard for machine and equipment connectivity. Han connectors feature modular inserts that allow power, signal, data, and pneumatic connections in a single housing.
Phoenix Contact excels in DIN-rail terminal blocks, PCB connectors, and industrial circular connectors. Their M8 and M12 circular connectors are standard in industrial automation, sensor connectivity, and fieldbus networks.
Connector Families by Function
Board-to-Wire Connectors
These connectors join a wire harness to a printed circuit board. They are available in through-hole and surface-mount variants with pitches ranging from 1.0 mm to 5.08 mm. Common examples include Molex KK 254, JST XH, and TE MTA-100. Selection criteria include pitch, current rating, number of positions, and whether the application requires a locking mechanism to prevent accidental disconnection.
Wire-to-Wire Connectors
Wire-to-wire connectors join two harness segments or a harness to a sub-assembly. They typically feature a male housing and a female housing that click together. Molex Mini-Fit Jr., JST VH, and TE Universal MATE-N-LOK are popular choices. Key selection factors are current capacity per contact, wire gauge range, number of circuits, and environmental sealing requirements.
Circular Connectors
Circular connectors provide excellent resistance to vibration, shock, and environmental exposure thanks to their round, threaded, or bayonet-locking interfaces. They are standard in military (MIL-DTL-5015, MIL-DTL-38999), aerospace, industrial machinery, and outdoor equipment. Amphenol, Souriau, and ITT Cannon are prominent suppliers. IP67 and IP68 ratings are common for sealed variants.
Rectangular / Multipole Connectors
Rectangular connectors like the Harting Han series house multiple contacts in a compact rectangular frame. They are ideal for industrial machinery and equipment where a single connector must carry a combination of power, signal, and data lines. Modular insert systems allow customization without designing a connector from scratch.
D-Sub Connectors
D-subminiature connectors, originally developed for computing interfaces, remain widely used for RS-232 serial communication, industrial control panels, and instrumentation. Available in standard sizes (DB-9, DB-15, DB-25, DB-37, DB-50), they can carry signal, power, or a combination. High-density versions pack more contacts into the same shell size.
How to Choose the Right Connector
Start with the electrical requirements: current per contact, voltage rating, and number of circuits. Then evaluate the environment: will the connector face moisture, dust, chemicals, UV exposure, or extreme temperatures? Consider the mechanical demands: vibration, mating cycles, cable pull-out forces, and panel-mount or free-hanging installation. Finally, factor in serviceability—does the end user need to connect and disconnect the harness regularly, or is it a permanent installation? For answers to common questions about connector selection and harness design, check our frequently asked questions page.
Cost and lead time also influence the decision. Standard catalog connectors from major brands typically offer better pricing and availability than custom solutions. However, specialized applications sometimes demand proprietary or application-specific connectors.
At SIMKAB, we work with all major connector brands and families to build harnesses that meet your exact specifications. Our engineers can recommend the optimal connector for your application based on decades of manufacturing experience. Browse our services to learn how we support projects from prototype through volume production, or get a quote to start your next wire harness project today.
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