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Solderless Magnet Wire Termination Solutions

TE Connectivity (TE) provides high-quality, cost-effective terminating solutions tailored for motor, coil, and solenoid applications. Explore our robust portfolio of magnet wire solutions.

Benefits that Drive Better Manufacturing

reduce

Reduce Process Steps

Controls stripping
and soldering.

improve

Enhance Repeatability

Consistent connections across production runs.

support

Support Automation

Compatible with automated or semi-automated tooling.

lower

Cost Effective

Helps reduce labor, rework
and process variability.

conduct

Conduct Material Flexibility

Solutions for copper or aluminium wire

Why Switch from Soldered to Solderless Termination?

Traditional soldering adds process steps, variability and heat stress. TE solderless solutions help you build better products, faster and more cost-effectively.

VS

Traditional Welding/Soldering

  • cross-red For applications requiring wire preparation (stripping)
  • cross-red Labor-intensive, multi-step process that is difficult to automate, scale, and maintain efficiently
  • cross-red Greater variability, rework risk, and challenges maintaining consistent termination quality
  • cross-red Heat and chemical-dependent process with environmental and thermal concerns
  • cross-red Very difficult to terminate aluminum magnet wire; copper is typically the only practical option

TE Logo TE Solderless Solution

  • tick No pre-stripping required
  • tick Streamlined, automation-ready solution with fewer process steps, help in reducing labor costs while increasing scalability and throughput
  • tick Repeatable process delivering consistent, high-quality connections
  • tick No heat, chemicals, or solder required, significantly reducing thermal damages and fumes
  • tick Connects both copper and aluminum magnet wire with stable, gas-tight terminations

How Solderless Magnet Wire Termination Works

Solderless terminals can be terminated using various methods, including Insulation Displacement Contact (IDC) and Open-Barrel Crimping depending on the application requirements.

Insert Magnet Wire

The unstripped magnet wire is positioned into the termination slot.

Magnet wire positioned in the termination slot

Insert Terminal into Cavity

The terminal is pushed into the cavity by a specially designed insertion tool. During this insertion, specially designed contact features penetrate the enamel insulation layer of the magnet wire.

Terminal being inserted into the cavity

Create Electrical Contact

Once inserted, the terminal is retained by locking barbs, and its contact features establish a reliable electrical connection.

Completed terminal electrical contact

Application Tooling Options for Magnet Wire Terminations

Explore the manual, semi-automatic, and automatic application tooling solutions for our solderless terminals.

Arbor Press + Fixturing

Machine Rate (estimated):
60 crimps/hour
Price Range (estimated):
$2,000 - $4,000, depending on complexity
Purchase From:
TE
Lead Time:
8 weeks
Additional Information:
  • TE will offer custom configurations based on customer needs
  • Customer intake form
Arbor Press + Fixturing

Inserter Machines

Machine Rate (estimated):
600+ crimps/hour, depending on complexity
Price Range (estimated):
$10,000 - $25,000, depending on complexity
Purchase From:
Recommended partners:
  • Sipro (Americas & EMEA)
  • Zhanxu (Asia)
Lead Time:
12-20 weeks, depending on complexity
Additional Information:
Customizable, semi-automatic machine
Inserter Machines

Custom Work Stations

Machine Rate (estimated):
1500+ crimps/hour, depending on complexity
Price Range (estimated):
$50,000+, depending on complexity
Purchase From:
Recommended partners:
  • Sipro (Americas & EMEA)
  • Zhanxu (Asia)
Lead Time:
20+ weeks, depending on complexity
Additional Information:
Customizable, automated workstations
Custom Work Stations

Enhance Motor Designs with Advanced Termination Solutions

Discover how manufacturers are enhancing motor designs and cutting costs with TE Connectivity’s robust portfolio of MAG-MATE and SIAMEZE terminals for Aluminum Magnet Wire. Enhance your processes with noteworthy termination solutions tailored to today's needs. Explore efficient magnet wire connections for motors, compressors, transformers, and other windings.

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Expert Resources to Guide Your Design Decisions

Access white papers, guides and case studies.

View All Resources
Case Study

Solderless Magnet Wire Solutions for Heat Pump Compressors

A case study series covering solutions to improve electric motor manufacturability in Heat Pump Compressors.

Read Case Study
White Paper

Smarter Interconnections for Humanoid Robotics

Discover how advanced solderless solutions and smarter magnet wire designs can unlock faster innovation and scalable robotics manufacturing.

Download
White Paper

MAG-MATE Terminals for Over-Molding Applications in Appliance Motors

Explore design considerations on motor manufacturing with MAG-MATE solderless magnet wire solutions in bulk molding compound (BMC) over-molding environments.

Download
Case Study

Solderless Magnet Wire Solutions for Electric Vehicle Systems

Learn more on how solderless connectivity is reshaping EV sub-system assembly and production efficiency.

Read Case Study
Case Study

Solderless Magnet Wire Solutions for Power Tool Motors

Learn more about our solderless magnet wire solutions and how they can help improve efficiency during electric motor manufacturing.

Read Case Study
Case Study

Solderless Magnet Wire Solutions for Electric Bicycle Motors

Learn more about how these solderless solutions can be used in electric bicycle motor applications.

Read Case Study
White Paper

Solderless Magnet Wire Solutions for Ceiling Fan Motors

An overview of TE Connectivity's IDC technology and its role in improving efficiency, noise reduction, and service life in ceiling fan motors.

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White Paper

Solderless Magnet Wire Solutions for Fan Motors

Explore how magnet wire solderless connectivity solutions address the evolving requirements of fan motor manufacturing.

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Trend Paper

Market Trends in Washing Machine Motor Design

Discover the latest trends in washing machine motors with TE's solderless magnet wire solutions, reducing manufacturing time and costs while streamlining motor assembly automation.

Download

Need Help Selecting the Right Magnet Wire Solution?

Our product experts can help you select the right terminal, tooling and process for your motor design and production needs.

Savings Calculator

Calculate potential savings with TE's MagWire Termination Solutions.

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Contact Our Product Team

Get expert support for your application.

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Explore All Products

View the complete range of magnet wire terminals.

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