Hexagonal Crimp vs. B-Crimp in Wire Harness Manufacturing

Hexagonal Crimp vs. B-Crimp in Wire Harness Manufacturing

Two commonly used crimping methods are hexagonal crimp and B-crimp. Both are widely applied in electrical connections, but their performance can vary depending on the cable structure and operating conditions.

This article compares the two crimping methods based on key performance factors such as strand compaction, electrical resistance, temperature rise, and suitability for flexible cable harness production.

Why Flexible Cables Create Crimping Challenges

Flexible cables contain a large number of fine strands designed to improve bending performance and vibration resistance. While this structure provides excellent flexibility, it also makes the crimping process more complex.

After stripping the insulation, the strands of a flexible cable tend to expand and occupy more space inside the terminal barrel. If the crimp structure cannot compress the strands efficiently, internal voids may remain between the conductors.

Insufficient strand compaction can lead to:

● increased electrical resistance

● higher operating temperatures

● reduced vibration resistance

● long-term reliability problems

Therefore, the effectiveness of a crimp structure largely depends on how well it compacts flexible strands and eliminates internal gaps.

Hexagonal Crimp vs. B-Crimp: Key Differences

Hexagonal crimps compress the terminal into a hexagonal shape, which works well for cables with fewer and thicker strands.

However, when applied to flexible cables with many fine strands, this structure may create small voids between strands, reducing electrical contact.

Why B-Crimp Works Better for Flexible Cables

B-Crimp technology is designed to compress the wire strands more evenly inside the terminal barrel.

This improves:

● Strand contact

● Electrical conductivity

● Mechanical stability

Because of these advantages, B-Crimp is commonly preferred in industries using flexible cables, such as:

● Automotive wire harness

● Electric vehicles

● Railway systems

● Aerospace wiring

● Industrial automation equipment

Temperature and Electrical Performance

Poor strand contact increases electrical resistance, which may lead to higher temperatures during current transmission.

In flexible cable applications, B-Crimp connections typically provide:

● Lower crimp resistance

● Better heat dissipation

● More stable electrical performance

This helps reduce the risk of overheating and improves long-term reliability.

Role of Automatic Crimping Machines

To ensure consistent crimping quality, many manufacturers use automatic wire cutting and terminal crimping machines in production.

Modern crimping equipment can:

● Automatically cut and strip wires

● Precisely control crimping force

● Ensure stable B-Crimp formation

● Improve production efficiency

These machines are widely used in high-volume wire harness manufacturing lines.

Conclusion

Both Hexagonal Crimp and B-Crimp have their applications in wire harness manufacturing.

However, for flexible cable systems commonly used in modern industries, B-Crimp generally provides better strand contact, lower resistance, and improved thermal performance.

Selecting the correct crimping method, combined with reliable automated crimping equipment, is essential for ensuring stable electrical connections in wire harness production.