10 Most Common Connector Types for Wire Harness & Cable Assembly

Choosing the right connector can make or break your wire harness design. After specifying thousands of connectors over 15 years, I've learned that connector selection is where most project delays and cost overruns originate. Pick wrong, and you're looking at redesigns, long lead times, or field failures.

This guide covers the 10 most common connector types we use in production, organized by manufacturer and application. I'll share the real-world performance data, typical applications, and the gotchas that spec sheets don't mention.

1. Molex Connectors

Molex is often the first name engineers think of for wire-to-board connections. Founded in 1938, they've become the de facto standard for consumer electronics, appliances, and automotive interior applications.

Popular Molex Series:

Pro tip: Molex Micro-Fit 3.0 is my go-to recommendation for general-purpose internal wiring. Reliable locking mechanism, widely available, and the crimping tools are reasonably priced. The 5A rating handles most signal and moderate power applications.

2. JST Connectors

JST (Japan Solderless Terminal) dominates the small-pitch, low-power connector market. If you've ever opened a laptop, drone, or lithium battery pack, you've seen JST connectors.

Popular JST Series:

Watch out: JST connectors have tight tolerances. Poor-quality crimping or non-genuine housings cause intermittent connections. We only use genuine JST components and JST-approved crimping tools for production harnesses.

3. TE Connectivity (Formerly AMP/Tyco)

TE Connectivity is the largest connector manufacturer globally. Their portfolio spans from delicate signal connectors to heavy-duty power terminals. If you're working on automotive, aerospace, or industrial equipment, you'll encounter TE products constantly.

Key TE Product Lines:

4. Amphenol Connectors

Amphenol specializes in rugged, high-reliability connectors for demanding applications. When failure isn't an option—aerospace, military, medical—Amphenol is often the specified brand.

Notable Amphenol Products:

• Amphenol Industrial: Heavy-duty circular connectors for industrial automation and power distribution
• Amphenol Aerospace: MIL-SPEC circular connectors (D38999, MIL-DTL-26482)
• Amphenol RF: Coaxial and RF connectors for telecommunications
• Amphenol ICC: High-speed data connectors for servers and networking

Reality check: Amphenol connectors command premium pricing—often 2-3x equivalent consumer-grade options. But for certified aerospace or medical applications, the quality documentation and traceability justify the cost.

5. Deutsch Connectors

Deutsch connectors (now part of TE Connectivity) are the gold standard for heavy-duty vehicle and equipment wiring. If you work with trucks, construction equipment, or agricultural machinery, Deutsch DT, DTM, and DTP series are your bread and butter.

Why we love Deutsch: Field serviceability. The wedgelock design means you can remove and re-insert terminals without special tools. When equipment is in the middle of a construction site or farm, that matters.

6. Circular Connectors

Circular connectors provide 360-degree shielding and are inherently more resistant to vibration than rectangular designs. They're the connector of choice for military, aerospace, and industrial equipment.

Common Standards:

• MIL-DTL-38999: High-performance military standard, scoop-proof, multiple shell styles
• MIL-DTL-5015: Standard-duty military circular, threaded coupling
• MIL-DTL-26482: Miniature circular, aerospace applications
• Industrial circular: Brands like Amphenol C091, TE CPC

7. D-Sub Connectors

D-subminiature connectors have been around since the 1950s, and they're still everywhere—RS-232 serial ports, industrial controls, legacy equipment interfaces. The distinctive D-shaped shell prevents mis-mating.

Standard configurations: DB9, DB15, DB25, DB37, DB50. The number indicates pin count. Despite being "legacy," we produce thousands of D-sub harnesses annually for industrial control and test equipment applications.

8. M12 and M8 Industrial Connectors

M12 and M8 connectors dominate factory automation. They're the standard interface for sensors, actuators, and industrial Ethernet. The threaded coupling provides reliable connection in high-vibration environments.

M12 Coding Types:

Key suppliers: Phoenix Contact, TE Connectivity, Binder, Murr Elektronik. We stock multiple brands to match customer specifications and availability.

9. Terminal Blocks

Terminal blocks aren't technically connectors in the traditional sense, but they're essential for control panel wiring and field connections. They allow multiple wires to be connected, disconnected, and rerouted without soldering.

Major types include screw terminals (reliable, require screwdriver), spring-cage (tool-free, faster installation), and push-in terminals (quick connect for solid wire). Brands like Phoenix Contact and WAGO lead the market.

10. Automotive RF Connectors (FAKRA/Mini-FAKRA)

FAKRA connectors are the automotive industry standard for RF applications—GPS, satellite radio, cellular, camera systems. The color-coded housings prevent cross-connection and are keyed for specific applications.

Mini-FAKRA (also called HFM) is the next generation, offering 4x higher density than standard FAKRA. We're seeing increasing demand for Mini-FAKRA as vehicles add more cameras and sensors.

How to Choose the Right Connector

When selecting connectors for your wire harness or cable assembly, consider these factors:

1. Current and Voltage Requirements: Always derate from datasheet maximums. Environmental factors (temperature, altitude) reduce capacity.
2. Environmental Conditions: IP rating requirements, temperature range, chemical exposure, vibration levels.
3. Mating Cycles: How often will the connector be connected/disconnected? Consumer products need maybe 100 cycles; test equipment might need 10,000+.
4. Size and Density: Available space, wire gauge, number of circuits needed.
5. Industry Standards: Automotive often mandates specific connector families. Aerospace requires MIL-SPEC qualified parts.
6. Cost and Availability: Exotic connectors may perform better but cost more and have longer lead times. Sometimes "good enough" is the right answer.

Partner with the Right Manufacturer

Connector selection is just the beginning. Proper crimping, testing, and quality control are what separate a reliable harness from a failure waiting to happen.

At our facilities, we maintain tooling and expertise across all major connector families. Whether you need a simple JST battery cable or a complex automotive harness with Deutsch sealed connectors, we've got the capabilities and experience to deliver.