Assemble cables yourself or buy them ready-made?
Whether you assemble cables yourself or buy ready-made leads depends on quantity, the required IP rating and quality assurance. This guide gives you clear decision criteria, a cost example and the norm requirements for testing.
View connectivity productsWhen does DIY pay off and when do you buy ready-made?
The choice comes down to three factors: quantity, the required IP rating and quality assurance. Small batches and custom lengths favour DIY, while high volumes and sealed connectors favour ready-made leads.
Assembling cables yourself gives full control over length and pin assignment and is fast for prototypes, repairs and small series. Ready-made leads deliver reproducible quality, documented testing and sealed overmoulds that are hard to achieve by hand.
What does quality assurance mean for crimp and overmould?
A reliable crimp only forms with the right tool and correct crimp height. DIN EN 60352‑2 describes solderless crimping and the related tests such as pull-out force and crimp height.
- Calibrated crimp tool or machine with defined crimp height instead of a universal plier.
- Check and record the pull-out force for each cross-section.
- Micro-section or visual check for four to six visible strands in the crimp barrel.
- For IP67/IP68, add a leak test of the overmould.
- Continuity and insulation test on every finished lead.
When does DIY assembly pay off financially?
Count not only material but also tooling, labour, scrap and testing effort. A calibrated crimp tool quickly costs several hundred euros and a machine far more - these fixed costs only spread out across the quantity.
Example: for 20 leads of an unusual length and only IP20, DIY pays off because no sealed overmould is needed. For 500 identical IP67 sensor leads, ready-made is cheaper and safer because automated crimping and leak testing are included.
Frequently asked questions
From what quantity does ready-made pay off?
As a guide, from about 50 identical leads, because the tooling and setup cost of automated crimping is then amortised. With high IP requirements ready-made can make sense even sooner.
Can I assemble IP67 leads myself?
Field-attachable connectors realistically reach IP54 to IP67 in the field, but true overmoulded IP67/IP68 sealing is only reliable from the factory. For permanently sealed connections ready-made is the safe choice.
Which norm applies to crimp connections?
DIN EN 60352‑2 governs solderless crimp connections including tests such as crimp height and pull-out force. Tool calibration and test records also matter for the workstation.
Do I need special tools for DIY assembly?
Yes, a calibrated crimp tool with the right die for the contact and cross-section is mandatory. Universal pliers do not produce a reproducible crimp height and jeopardise contact reliability.
Assemble yourself or buy ready-made?
We supply connectors, contacts and crimp tools for in-house assembly as well as tested, made-to-measure ready-made leads.
100 % tested
Ready-made leads with documented test records.
Sealed overmould
IP67/IP68 reliably overmoulded at the factory.
Norm-compliant
Crimping to DIN EN 60352-2.
Expert advice
We help you choose between DIY and ready-made.