Introduction
“DuPont connector” is a vernacular term which refers to a number of different types of 0.1″ pitch connector. They feature black plastic housings which retain contacts with fingers built into the housing body. All are very similar in appearance but vary significantly in quality and price.
There are various other names often attached to these, such as “TYU Connector” or “JWT Connector” (drop a comment if you know of another). These are acronyms for some of the many Chinese manufacturers, sometimes physically moulded into the product.
In some cases “DuPont connector” may refer to unrelated connector types which vaguely resemble the original design, however are significantly different in detail. Chinese reproductions of Molex SL / AMPMODU MTE and Molex CGrid III are some examples. On this page I’ll be sticking to the original series, and close look-a-likes.
Contents
- Mini-PV – The original “DuPont” connector (rarely used by hobbyists)
- Harwin M20 “DuPont” clone type (most common type used by hobbyists)
- Mixing Mini-PV and M20 contacts and housings
- Berg/DuPont “Maxi-PV”
Mini-PV – (Amphenol ICC – formerly FCI, formerly DuPont Connector Systems, formerly Berg)
Mini-PV was the first 0.1″ (2.54mm pitch) design of this type likely introduced in the 1950s by Berg Connectors which appears to have spent much of its life as a division of E. I. du Pont de Nemours and Company. Its contact measures 1.25mm square and features an elaborate bi-metallic design with a brass contact body and a beryllium alloy spring. As the heading suggests it has changed hands a few times since then.
The original Mini-PV family is still manufactured today by Amphenol in the USA, but is a fairly premium product which is not marketed for hobbyist use, and is priced accordingly, as one would expect for a product which has been produced by Uncle Sam to same specification for more than 70 years. In subsequent decades its design as been copied and altered by other parties.
I found Amphenol ICC’s website quite difficult to navigate, with catalogues incomplete, publicly available datasheets and documentation at best sporadic, and virtually non-existent for tooling. On this page I have summarised the parts which may be of interest to hobbyists who aren’t on a tight budget.
The most interesting feature is variable spring tension. I use “Ultra-high” types (48257-000LF) as it is rare that I build anything requiring more than 6-8 positions in one connector, and the higher disconnection force eliminates the need for latching.
In practice these should have been labelled “low”, “medium” and “high” as the “standard” type is not standard at all, it is actually a specialty contact which only makes sense in connectors with large numbers of positions.
Spring tension is rated for 1000 mating cycles.
Example part numbers
Numbers in bold can be changed to order connectors with a different number of positions. Note that some don’t correspond to the number of positions, I’ve added a few examples of these to show how to work out the needed part number.
| Housing 1×1 position (quite expensive for some reason?) | 65039-036LF |
| Housing 2×1 position | 65039-035LF |
| Housing 3×1 position | 65039-034LF |
| Housing 1×3 position polarised | 78211-003LF |
| Housing 2×2 position | 65043-035LF |
| Housing 3×2 position | 65043-034LF |
| Polarising blank plug | 65307-001LF |
| Female contact AWG 22-26 (‘ultra high’ mating force, 15µ Gold) | 48257-000LF |
| Female contact AWG 22-26 (‘high’ mating force, 15µ Gold) | 48254-000LF |
| Female contact AWG 22-26 (‘ultra high’ mating force, Tin) | 47750-000LF |
| Female contact AWG 22-26 (‘high mating’ force, Tin) | 47715-000LF |
| Female contact AWG 28-32 (‘high mating’ force, 15µ Gold) | 48254-000LF |
| 36 pin single row snap off header (15µ Gold) | 77311-818-36LF |
| 36 pin single row snap off header (Tin) | 77311-418-36LF |
| 36 pin single row snap off header – long 10mm mating pins (15µ Gold) | 77311-832-36LF |
| 72 pin dual row snap off header (15µ Gold) | 77313-818-72LF |
| 72 pin dual row snap off header (Tin) | 77313-418-72LF |
| 3 position polarised vertical header (15µ Gold) | 69167-103HLF |
| 3 position polarised right angle header (15µ Gold) | 78208-103HLF |
Cut strip / loose piece
The female contact part numbers I’ve listed are for pre-cut (loose piece) packaging. They are considerably cheaper if purchased as “cut strip” (reel packaging) however note that these are designed to be crimped by a “feed through” applicator, which means that cutting them for use in hand tools is quite time consuming.
Part numbers are in the catalogue. Note that distributors such as Mouser and Digi-Key only stock a very limited range of these contacts in “cut strip” form.
Wire-to-wire system
Mini-PV also features a wire-to-wire family. I’ve not been able to find a catalogue which gives an overview of this family. It uses the same female contact as the wire-to-board system, but introduces a male contact and different housings.
The same housing is used for both male and female contacts, with the housings containing male contacts having a shroud permanently latched to it (and rather difficult to remove once fitted) – sold separately. The shrouds latch into the contact opening, not the tabs on the side, same for the mating connector friction latch, so will also latch onto regular unpolarised housings no problem. They latch onto “DuPont” clone housings too.
I found the quality of these to be quite good, comparable to Molex SL (also featuring a high quality wire-to-wire option). Tolerances are tight, and disconnection force is considerable, especially when loaded with ultra high force spring contacts. The dual row types appear to be unique. I’ve not found any other example of a dual row 2.54mm pitch wire-to-wire connector of this style.
If already invested in this system, these are well worth considering however note that 8 positions is the maximum available, and as is always the case with this family, they’re not cheap.
Example part numbers
Numbers in bold can be changed to order connectors with a different number of positions. They are available in single row 2-4 position configurations, and dual row 4-8 position configurations with part number suffixes ranging from 001LF to 003LF for each type.
| Wire-to-wire housing 2×1 position | 67954-001LF |
| Male connector shroud 2×1 position | 67955-001LF |
| Wire-to-wire housing 2×2 position | 68105-001LF |
| Male connector shroud 2×2 position | 68106-001LF |
| Male contact AWG 22-26 (30µ Gold) | 75967-112LF 75967-312LF |
| Male contact AWG 28-32 (30µ Gold) | 75967-111LF 75967-311LF |
| Male contact AWG 22-26 (Tin) | 75653-002LF |
Crimp tools
If you can afford to use these connectors, you’ll also be able to afford to buy the appropriate tools to crimp them, even if only second hand – they are well worth it. I have confirmed six types:
- HT-95 (AWG 22-32): The current and most commonly used Mini-PV tool. It’s large and expensive but crimps these contacts to perfection.
- HT-102 (AWG 22-32): Same as the HT-95 but has a modified locator for male contacts.
- HT-73 (AWG 18-20): For ridiculously large wire sizes.
- HT-112 (AWG 34-36): For tiny wire sizes. Tool and contacts are special order only.
- HT-208A (AWG 22-26): Single die hand tool. Discontinued.
- HT-213A (AWG 28-32): Single die hand tool. Also discontinued.
I’ve not been able to work out what the exact use-case for the HT-73 tool is, given that the wires it crimps are too large to fit into Mini-PV housings. Uninsulated single terminations perhaps?
I’ve not ever been able to find an exhaustive list of all of the DuPont crimp tools and accompanying documentation. Some datasheets are available, but aren’t necessarily much help. There are many other HT-xxx tools in addition to what I’ve listed, all for sale on eBay in various quantities and states of repair. Most of these are for the obscure Maxi-PV family but there are many other types too, likely for obscure, largely forgotten former DuPont connector products.
The price of the most commonly used HT-95 tool brand new seems to fluctuate between high and extremely high. I have seen it sold for as little as $800, as high as $1600.
Example crimps
It is possible to crimp AWG 22-26 contacts in the AWG 28-32 die of the HT-95/102 tools however they will “extrude” (elongate) significantly, potentially beyond the end of the housing insulation once inserted.
Old single die tools
I am uncertain as to why DuPont offered two different series of tools for one connector family. The ergonomics of these tools is vastly superior to HT-95/102, but results are tiny bit rougher. They were discontinued decades ago, and may have been offered as a more affordable alternative the tools I mentioned earlier, however I cannot confirm this as it appears that no pricing information remains in the public domain.
If you do buy one, expect to have to do some repair work on it. I had to re-mount the spring and replace the original locator with a 1×1 housing on both of mine.
Oddball crimp tools
In addition to the tools detailed above, there are a further 4 specialties:
- HT-66 (AWG 22-26): The locator and right hand die in this tool is the same as that of the AWG 22-26 die in the HT-95. In this respect, it is half of an HT-95, and all of an HT-208. The left hand die is also an AWG 22-26 die however features a significantly larger insulation crimper. It is labelled “COAX INSULATION” implying a particularly large diameter insulation. I am uncertain what the use-case of this larger die is, as crimped contacts do not fit into Mini-PV housings.
- HT-68: (AWG 28-32): This is the companion tool of the HT-66 containing two AWG 28-32 dies. The right hand is the same as the AWG 28-32 die of the HT-95 and HT-213. The left hand is labelled “COAX INSULATION” and crimps wire with the same ridiculous insulation size as the HT-66 is intended for. Once again, use-case unknown.
- HT-86: A bare conductor crimper for AWG 18-20 or 22-26 contacts (works best with 22-26). It has quite a large conductor crimper, around AWG 18-20 but a small adjustable insulation crimper, with the intention of crimping the insulation part onto an AWG 18-20 (ish) bare conductor. Crimping the shield of a coaxial cable into a contact is a likely use-case.
- HT-94 (AWG 22-32): This is the most peculiar crimp tool of the lot. It contains exactly the same dies as the HT-95 but a very different locator which bends an offset into the contact while crimping, allowing crimped contacts to be stacked on top of one another. I am uncertain as to how these would be used in practice as the distortion of the contact means they don’t fit into Mini-PV housings.
