How much does a connector actually cost?

Connectors are often selected based on purchase price without adequate consideration of the costs associated with using them. How much does a connector actually cost?

Have you ever purchased the lowest priced item, only to find that the cost of using or owning it was much higher than you expected? This is often the case with connectors: they are often selected based on their purchase price, without adequate consideration of the costs associated with using them.

All connectors, whether wire-terminated or board-mounted, have additional costs associated with them. Some costs are well known, while others are hidden.

The total connector cost is usually divided into three categories: known cost; cost that can be determined with some effort; and cost that can only be known after use and experience.

1. Known cost

Piece-rate pricing for parts, including list price, negotiated price, EAU (estimated annual usage), or special quantities. Connector companies often outsource wire harness and printed circuit board manufacturing, including connector assembly. When this happens, even the purchase cost of the connector may be hidden.

Special packaging. Compatibility with application equipment or processes is sometimes required, such as wrapping paper, spools, tubes, pallets, tapes, etc.

Freight. Standard or expedited, domestic or international shipping.

Tooling costs for custom designed connectors. This cost can be paid directly or spread into the price of the connected device.

2. Cost determined after certain efforts

Registration fee. All connectors, whether terminated on a wire or mounted on a printed circuit board, have an application cost. Some application fees include:

Wire termination labor costs. Wire cutting and stripping, terminal crimping, soldering, welding, screw clamping, insertion, terminal insertion into housings, Insulation Displacement (IDC) terminations, and more.

Wire Termination Application Tool Cost. Wire cutting and stripping machines, crimping machines, contactor application machines, IDC machines, hand tools, insertion tools, extraction tools, etc.

PCB Installation Connector Labor Cost. Physically pick, orient and place connectors in the correct location. It may be manual placement or many levels of automation.

PCB Installation Connector Tool Cost. Fixtures, feeding mechanisms, placement machines, robots, end effectors, crimping machines, etc. Since connectors are often considered to have odd form factors, they may require custom tooling to handle them.

Tooling maintenance costs. In addition to the application machine itself, there is also the cost of tooling which is classified as a consumable. This is the tool that contacts the connector and will wear out over time. It consists of a crimping machine, anvil, peeling blade, feeding mechanism, guide rail, etc. Consumable tools are typically purchased and replaced by the end user. For some types of connectors, the life of consumable parts can be very short.