Jumper Wires, Pre-Crimped Leads

Part Number	Description / PDF	Quantity
G125-MW10450L94 Harwin	1.25MM M ON 26AWG 450MM	0
M40-9010099 Harwin	FEMALE CRIMP CONTACT CABLE ASSY	443
G125-MW10150L94 Harwin	1.25MM M ON 26AWG 150MM	364
G125-FW30450L94 Harwin	1.25MM F ON 30AWG 450MM	0
M40-9030099 Harwin	M40-100 SKT/FREE 32AWG 320MM	0
G125-MW10300F94 Harwin	1.25MM M/F ON 26AWG 300MM	51
G125-FW10150F94 Harwin	1.25MM F/F ON 26AWG 150MM	0
G125-FW10300F94 Harwin	1.25MM F/F ON 26AWG 300MM	889
G125-FW30150L94 Harwin	1.25MM F ON 30AWG 150MM	0
G125-FW10450L94 Harwin	1.25MM F ON 26AWG 450MM	300
M80-9220099 Harwin	M80-011 SKT/SKT 22AWG 300MM	312
G125-MW20300M94 Harwin	1.25MM M/M ON 28AWG 300MM	0
M40-9000099 Harwin	FEMALE CRIMP CONTACT CABLE ASSY	3542
M80-9180099 Harwin	M80-011 SKT/SKT 22AWG 150MM	173
M40-9070099 Harwin	M40-100 SKT/SKT 32AWG 320MM	325
M80-9230099 Harwin	F CBL CRMPD CONTACT	0
M80-9160099 Harwin	F CBL CRMPD CONTACT	194
M30-9000099 Harwin	M30-100 SKT/FREE 26AWG 150MM	0
M80-9150099 Harwin	F CBL CRMPD CONTACT	140
M80-9190099 Harwin	F CBL CRMPD CONTACT	133

Jumper Wires, Pre-Crimped Leads

1. Overview

Jumper wires and pre-crimped leads are essential components in electrical and electronic systems, providing flexible, reliable connections between devices, circuits, or components. These cable assemblies consist of conductive wires terminated with crimped connectors or contacts, enabling quick and secure electrical connections without soldering. Their importance spans industries such as telecommunications, automotive, industrial automation, and consumer electronics, where modularity, ease of installation, and maintenance are critical.

2. Major Types and Functional Classification

Type	Functional Features	Application Examples
Single-Core Jumper Wires	Simplex conductors with insulation, ideal for low-current signal transmission	Prototyping breadboards, PCB interconnects
Multi-Core Cable Assemblies	Multiple insulated conductors bundled in a common jacket for parallel signal/data transmission	Computer peripherals, industrial sensors
Shielded Jumper Cables	Integrated electromagnetic interference (EMI) shielding for noise-sensitive applications	Audio equipment, high-speed data lines
High-Temperature Leads	Heat-resistant materials (e.g., silicone rubber or PTFE insulation) for extreme environments	Automotive engine control units, aerospace systems
DIN/Standardized Connectors	Compliant with IEC/DIN standards for universal compatibility	Medical devices, test equipment

3. Structure and Components

A typical jumper wire or pre-crimped lead assembly consists of three primary elements:

Conductor: Stranded or solid copper wire (e.g., AWG 20-28) for optimal flexibility and conductivity.
Insulation: Thermoplastic (PVC, TPE) or high-temperature materials (FEP, silicone) to prevent electrical leakage.
Crimped Termination: Pre-assembled contacts or connectors (e.g., pin headers, spade terminals) mechanically secured via crimping tools.

Additional features may include strain reliefs, color-coded jackets for circuit identification, and overmolded strain reliefs for durability.

4. Key Technical Specifications

Parameter	Importance
Conductor Gauge (AWG)	Determines current-carrying capacity and flexibility
Current Rating (A)	Maximum safe operating current
Voltage Rating (V)	Dielectric strength of insulation material
Temperature Range ( C)	Operational limits in harsh environments
Contact Resistance (m )	Affects signal integrity and power efficiency
Insulation Resistance (M )	Prevents leakage currents
Crimp Pull-Out Force (N)	Mechanical stability of termination

5. Application Fields

Electronics Manufacturing: PCB testing, jumper connections in consumer devices.
Automotive: Wiring harnesses for sensors, battery management systems.
Telecommunications: Patch cables for routers, switches, and base stations.
Industrial Automation: Connection of PLCs, HMIs, and motor drives.
Medical Devices: Patient monitoring equipment and diagnostic tools.

6. Leading Manufacturers and Products

Manufacturer	Representative Products
TE Connectivity	AMPMODU pre-crimped jumper cables, high-temperature automotive leads
Molex	Micro-Fit 3D pre-assembled jumper wires for industrial controls
Amphenol	RF coaxial jumper cables for telecom infrastructure
Phoenix Contact	Printed circuit board connectors with pre-crimped leads
3M	High-density shielded cable assemblies for data centers

7. Selection Guidelines

When selecting jumper wires or pre-crimped leads, consider:

Application Requirements: Signal type (analog/digital), voltage/current levels, and environmental conditions.
Compatibility: Connector types (e.g., USB, HDMI, proprietary headers) and mating cycles.
Cost vs. Performance: Balance material quality (e.g., oxygen-free copper) against budget constraints.
Supplier Support: Availability of customization, volume pricing, and technical documentation.

Case Study: In an automotive test system, shielded high-temperature leads with 16 AWG conductors and silicone insulation ensured reliable data transmission at 150 C.

8. Industry Trends

Miniaturization: Growth in ultra-fine AWG 34+ cables for wearable devices and IoT sensors.
High-Speed Data Transmission: Development of controlled-impedance jumpers for 10+ Gbps applications.
Automation Integration: Standardized pre-crimped leads compatible with robotic assembly systems.
Sustainability: Adoption of halogen-free insulation and recyclable materials.
Smart Cables: Embedded sensors for real-time monitoring of temperature and current.