Terminal Crimp
Cross Section Analysis

Terminal crimp cross section analysis showing crimp height and conductor compaction measurements

Precision Insights That Protect Your Production and Compliance

Quality begins at the crimp. Diamond Die & Mold’s terminal crimp cross section analysis service gives manufacturers and engineers precise visibility into crimp integrity, so you can confirm quality, meet industry standards, and catch problems before they reach the field.

Send us your samples. Our engineers prepare, analyze, and report on each crimp, delivering detailed measurements and expert interpretation. No capital investment in analysis equipment required. No wait for internal QC lab queues. Just clear answers from the team that has been designing terminal crimping tooling for 70 years.

Free Crimp Sample Review

What We Measure

Every sample analyzed includes measurements of:

  • Crimp height
  • Crimp width
  • Outside tracing area
  • Inside tracing area
  • Burr width
  • Conductor compaction
  • Strand count (limited in count due to size, as some cables have hundreds or thousands of strands).

These measurements give a complete picture of how the terminal has been compressed onto the wire and whether the crimp meets your specifications. Each measurement is documented in an individual sample report you receive after analysis.

Sample Range
Our system handles conductor sizes from 28AWG to 400 MCM.

Crimp Types Analyzed
We can analyze any style of crimp. Customer just needs to define dimensional and compaction requirements.

The Analysis Process

Our process is designed to be straightforward for you and rigorous in execution.

Step 1: Sample Preparation
Send us your crimped samples. Our team prepares each sample for analysis. We can analyze any style of crimp. Customer just needs to define dimensional and compaction requirements.

Step 2: Cross Section Analysis
Each sample is cut, polished, and imaged for cross section analysis. Our engineers measure the crimp geometry against specification tolerances and industry standards.

Step 3: Detailed Reporting
You receive an individual report for each sample analyzed, including all measurements, image documentation, and engineering interpretation of the results, if requested.

Turnaround:
1-3 weeks depending on workload and sample quantity.

No Cost Analysis

Why Crimp Analysis Production Matters

Crimp cross section analysis confirms that your crimping process delivers what your specifications require. Specifically, it helps you:

  • Confirm reliable wire-end crimps that will not fail in the field
  • Reduce defects and rework by catching process issues before production scale
  • Meet strict industry compliance standards
  • Improve long-term product safety and performance
  • Support automotive, EV, aerospace, medical device, and OEM manufacturing requirements

For manufacturers running high-volume production, this validation protects your reputation, your warranty exposure, and your customer relationships.

Built for the Industries
That Depend on Crimp Reliability

Terminal crimp cross section analysis supports quality validation across:
Automotive and EV
Manufacturing

Catches loose terminations, fatigued wires, and mismatches before they reach the production line, reducing warranty exposure on high-current battery systems and wiring harnesses.

Aerospace
Manufacturing

Confirms uniform compression, correct conductor brush configuration, and controlled crimp force for avionics, structural wiring, and mission-critical connections.

Medical Device
Manufacturing

Validates miniature crimps against spec, supporting the reliability and traceability requirements medical device teams face during audits.

Consumer Electronics and
Industrial OEMs

Catches wire pullout, contact resistance, and strand breakage risks before they affect field performance.

Why Choose Diamond Die & Mold for Crimp Analysis

Most competitors sell you the equipment to do crimp analysis in-house. That is a six-figure investment plus trained staff. Diamond Die & Mold offers on-demand analysis performed by the engineers who have been designing crimping tooling for 70 years.

Expert interpretation, not just automated measurements. Software gives you numbers. Our engineers tell you what the numbers mean for your production, if requested.

Applied crimping experience since 1956. Seven decades of designing the tooling that makes these crimps.

Full-loop support. If our analysis identifies a tooling issue, we can build the replacement.

Woman-Owned Small Business and ISO 9001 certified. Supports federal contract, aerospace, and medical device audit requirements.

Direct access to our engineering team. No sales layers, no chatbots, no wait.

Close-up of a modern pickup truck headlight at a three-quarter angle, representing Ohio's automotive manufacturing industry

Compliance and Industry Standards

Every analysis report includes the measurements, images, and documentation needed to support your quality audits and regulatory reviews.

Our standard report format references SAE/USCAR-21, the industry standard for automotive electrical terminal performance requirements. When your project requires a different format, our analysis system also supports OEM-specific report templates for VW, Bosch, PSA (Stellantis), Renault, Fiat, and other major manufacturers.

If your compliance requirement isn’t listed, contact our team. We can confirm which format best fits your project before you send samples.

What to Know About Crimp Cross Section Analysis

What is crimp cross section analysis?

Crimp cross section analysis is a validation method where a crimped terminal is cut, polished, and imaged to reveal the internal geometry of the crimp. Engineers measure the compression, strand deformation, and terminal geometry to confirm the crimp meets quality specifications.

How do I send samples for analysis?

Contact our team to discuss your samples and application. We will provide shipping instructions and confirm what specifications you want your samples measured against.

What wire and terminal sizes can you analyze?

We can analyze any style of crimp across a wide range of wire and terminal sizes. You define the dimensional and compaction requirements for your application, and our team will confirm we can support your samples before you send them in.

What does a completed analysis report look like?

Each report includes crimp height, crimp width, outside and inside tracing area measurements, burr width, conductor compaction, strand count, cross section imaging, and engineering interpretation of the results, if requested. Reports are delivered as individual documentation per sample.

Do you analyze crimps produced by other manufacturers' applicators and presses?

Yes. We analyze crimps regardless of which equipment produced them. Our team is often asked to validate crimps for OEMs auditing their suppliers, or for manufacturers evaluating a new applicator setup before scaling to production.

Can you help me fix problems the analysis identifies?

Yes. If our analysis identifies a tooling issue causing crimp defects, we can reverse engineer and build replacement tooling to fix the problem. Same team, same facility, same 70-year applied experience.

Explore Additional
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Reverse engineering is often the first step. Once your replacement tool is in production, most customers expand into one or more of these services to keep their operations running.

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Crimping Presses

6-ton and 22-ton presses matched to your terminal and applicator setup.

Perishable Tooling

High-precision replacement tooling built for repeat use in high-volume production.