How to calibrate for wiring, gauge and terminal reliability

Crimp calibration is a foundational practice for ensuring that wiring systems deliver consistent performance and long-term reliability. Whether you're working in aerospace, automotive, or industrial applications, ensuring terminal and gauge integrity is critical to maintaining both electrical performance and safety standards.

To be confident about reaching these requirements, engineers need to have an understanding of the practical steps and insights into effective crimp calibration. Alongside this, the role of UKAS-accredited calibration cannot be understated, particularly for high-stakes environments.

Why crimp tool calibration matters

Crimp connections are a common failure point in electrical systems. A poorly calibrated crimp tool can cause under or over-crimping, leading to loose connections, wire damage or increased resistance. This leads to intermittent faults, heat build-up or even total system failure. Accurate calibration ensures that every crimp meets defined standards for pull force, deformation and electrical conductivity.

Steps to calibrate crimp tools for reliability

1. Evaluate tool wear and compatibility

Before calibration begins, inspect crimp tools for wear. Dies should be clean and undamaged. Confirm the tool is compatible with the wire gauge and terminal type in use. Any misalignment here can introduce variability even before calibration starts.

2. Reference manufacturer specifications

Each tool and terminal has its own recommended crimp height and pull-out force. These figures should be the starting point for calibration, ensuring your output is within the specified tolerance range.

3. Conduct pull-out tests

Use a force gauge to verify the mechanical integrity of the crimp. If the wire pulls free too easily or not at all, adjustments are required. This test is critical for ensuring that crimps can withstand operational stress without detachment.

4. Check crimp height and width

Use micrometres or crimp profile gauges to measure the deformation of the terminal after crimping. These measurements need to be within defined tolerances to ensure proper electrical contact and mechanical reliability.

5. Repeat for all wire gauges and terminal types

Calibrate each unique combination of wire gauge and terminal. Each pairing behaves differently under pressure, and uniform settings across the board can lead to inconsistency.

6. Document results for traceability

Calibration logs must be detailed, noting test values, tool IDs, and environmental conditions. This supports traceability and ensures repeatable outcomes over time.

Where UKAS accreditation fits in for crimp tool calibration

While internal checks are important, relying on UKAS-accredited calibration offers unparalleled assurance. UKAS accreditation guarantees that the calibration process adheres to ISO 17025 standards, ensuring the equipment used in crimp testing is itself precisely verified.

This level of accreditation is particularly important for sectors that cannot afford even minor variances, such as aerospace, defence and medical manufacturing. UKAS-accredited calibration verifies tool accuracy, measurement traceability, environmental controls and technician competence.

Get industry leading calibration for your equipment

Crimp reliability starts with disciplined calibration. From verifying crimp height and pull-out force to maintaining tool integrity and traceability, consistent outcomes hinge on proactive practices. Following these steps ensures that your wiring systems remain dependable, compliant and free from performance issues that stem from avoidable errors.

At DM Systems & Test, we provide specialist calibration services for crimp tools across all wire gauges and terminal types. Our UKAS-accredited processes ensure total compliance and confidence in your results. With our mobile calibration units, we also bring lab-level precision directly to your facility, minimising downtime and ensuring production continuity.

Want to ensure your wiring systems are reliable, repeatable, and regulation-ready? Download our guide to crimp calibration and discover how DM can help you elevate your operational integrity.