High-Reliability Wafer Connectors Manufacturer (Wire-to-Board)
Tonful Electric is a premier manufacturer of precision Wire-to-Board Wafer Connectors, designed to deliver secure signal and power transmission in demanding environments. Available in industry-standard pitches ranging from 1.0mm to 3.96mm (including 1.25mm, 2.0mm, and 2.54mm), our wafer headers are engineered as perfect drop-in replacements for major global brands.
Built with high-conductivity brass contacts and durable, high-temperature insulators (LCP/Nylon), our wafer connectors feature robust friction lock or positive lock mechanisms to prevent accidental disconnection due to vibration. Whether you need standard Through-Hole (DIP) or Surface Mount (SMT) configurations, Tonful provides highly cost-effective, factory-direct solutions for automotive, home appliance, and industrial circuitry.
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Our Wafer Connectors Range
8Pin PH0.8mm Wafer Connector
PH1.0mm 90°SMT Wafer Connector
PH1.25mm SMT Wafer Connector
PH2.mm 90°DIP Wafer Connector
PH2.5mm DIP Wafer Connector
PH3.mm SMT Wafer Connector
PH3.96mm 90°DIP Wafer Connector
PH4.2mm 90°DIP Wafer Connector
Technical Specifications: Wafer Connectors (Wire-to-Board)
| Specification | Available Options / Parameters |
|---|---|
| Pitch Sizes (间距尺寸) | 1.0mm, 1.25mm, 1.5mm, 2.0mm, 2.5mm, 2.54mm, 3.0mm, 3.96mm |
| Mounting Orientation (安装方向) | Straight (180° Vertical), Right Angle (90° Horizontal) |
| Termination Style (焊接方式) | Through-Hole Technology (THT / DIP), Surface Mount Technology (SMT / SMD) |
| Contact Material (端子材质) | High-Conductivity Brass, Phosphor Bronze |
| Contact Plating (表面镀层) | Matte Tin, Bright Tin, Gold Flash (Customizable) |
| Insulator Material (塑胶材质) | Nylon 66 (PA66), PA6T, PA9T, LCP (High-temp for SMT) |
| Flammability Rating (阻燃等级) | UL94 V-0 |
| Locking Mechanism (锁扣类型) | Friction Lock (摩擦锁扣), Positive Lock (卡扣锁紧) |
| Current Rating (额定电流) | 1.0A to 7.0A Max (Depending on pitch size and wire gauge) |
| Cross-Reference (可替代品牌) | Drop-in equivalents for standard JST, Molex, TE, and JAE series |
Why Choose TONFUL Wafer Connectors
Seamless Cross-Reference Compatibility
We manufacture wafer connectors that are dimensionally and functionally equivalent to major international series (such as JST PH/XH, Molex KK/Micro-Fit, etc.). You get the exact same reliable performance and PCB footprint at a fraction of the cost, eliminating redesign efforts.
Secure Locking Mechanisms
To combat high-vibration environments in automotive and industrial equipment, our wafer connectors feature robust friction locks or positive snap-in locks. This ensures the mating wire housing "clicks" securely into place and will not disconnect under stress.
High-Temperature SMT Readiness
For automated Surface Mount Technology (SMT) assembly, our wafer headers utilize advanced plastics like LCP, PA6T, or PA9T. These insulators flawlessly withstand reflow soldering temperatures (up to 260°C) without blistering, melting, or warping.
Shrouded Housing Protection
Unlike exposed pin headers, our wafer connectors feature fully shrouded (boxed) plastic housings. This design prevents the metal pins from bending during handling and provides polarization to guarantee correct mating orientation (anti-misinsertion).
Tape & Reel Packaging for Automation
To maximize your manufacturing efficiency, all our SMT wafer connectors are available in professional Tape and Reel (T&R) packaging with pick-and-place caps, ensuring zero downtime on your automated PCB assembly lines.
Complete Wire-to-Board Solutions
Tonful doesn't just supply the PCB wafer header; we provide the complete connection system. We can supply the matching female crimp housings and metal terminal contacts, or even fully assembled custom wire harnesses, simplifying your supply chain.
Professional Selection Guide
Step 1: Identify the Pitch and Spacing
The pitch (e.g., 1.25mm, 2.0mm, 2.54mm, 3.96mm) is the most critical dimension. It determines the overall size of the connector and must match both your PCB footprint and the mating wire harness housing.
Step 2: Determine Current and Voltage Requirements
Select a connector size that safely handles your power needs. Smaller pitches (like 1.0mm/1.25mm) typically handle 1A to 2A for signal transmission, while larger pitches (like 3.96mm) can handle up to 7A for power delivery.
Step 3: Choose the Mounting Orientation
Decide how the wire harness should exit the PCB. Choose Straight (180° Vertical) if the wires should go straight up, or Right-Angle (90° Horizontal) if the wires need to run parallel to the board for low-profile enclosures.
Step 4: Select SMT or Through-Hole (THT)
Specify Through-Hole (DIP) headers for maximum mechanical strength in high-vibration applications, or select Surface Mount (SMT) headers for high-density, automated PCB assembly.
Step 5: Define the Locking Requirement
For static electronics, a standard friction lock is usually sufficient. However, for automotive, motors, or moving machinery, strictly specify a Positive Lock to ensure the connection cannot be pulled apart accidentally.
Step 6: Match the Mating Housing & Terminals
A wafer header is only half the solution. Ensure you also source the perfectly matched female plastic housing and the correct AWG crimp terminals to complete the wire-to-board connection securely.
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We provide samples for free, you just need to tell us what you need
MORE THAN JUST A WAFER CONNECTOR MANUFACTURER
Service Consultation
Whether your Wafer Connectors requirements are straightforward or complex, our team provides expert advice and technical consultation. For more intricate projects, we offer in-depth engineering support to ensure optimal product selection and application, guaranteeing safety and efficiency in your electrical systems.
Product Recommendations
Unsure which Wafer Connector suits your system? Our specialists provide free, customized recommendations based on your specific operational and environmental requirements, ensuring you get the perfect fit for your electrical protection needs.
Installation Support
Need help with installation? Our technical team is available to answer your questions or provide hands-on support. For larger projects, we can even dispatch an engineer to your site for on-the-ground assistance, ensuring your Wafer Connectors are installed correctly and function seamlessly within your electrical network.
Logistics Support
If you lack a reliable freight forwarder, we can arrange transportation from our factory to your project site at no extra cost. Our logistics team ensures timely and secure delivery to keep your project on schedule, minimizing downtime and delays.
Frequently Asked Questions
We have compiled some common questions from our clients. If your question isn’t included here, our customer service is always available to help. We’d love to talk with you.
Q1: Can your wafer connectors directly replace JST or Molex parts?
Yes. Our wafer connectors are precision-engineered as drop-in equivalents (cross-references) for many popular series, such as the JST XH (2.5mm), JST PH (2.0mm), and Molex Micro-Fit series. They fit the same PCB layout and mate with the original brand’s housings.
Q2: What is the difference between a Wafer Connector and a Pin Header?
While both have pins soldered to a PCB, a Pin Header is typically un-shrouded (bare pins) and mates with a female board socket (Board-to-Board). A Wafer Connector features a protective plastic “box” (shroud) with polarization and locking features, designed specifically to mate with a wire harness (Wire-to-Board).
Q3: Will the plastic housing melt during SMT reflow soldering?
Not if you select our SMT-specific wafer connectors. We use high-temperature plastics like LCP or PA9T for our SMT lines, which easily withstand standard lead-free reflow oven temperatures (up to 260°C). Our standard DIP connectors use Nylon 66, which is optimized for wave soldering.
Q4: Do you supply the matching wire housings and metal crimp terminals?
Absolutely. We offer the complete wire-to-board system. You can purchase the wafer headers, the empty female housings, and the reel of metal crimp terminals directly from Tonful. We can also provide fully assembled, custom wire harnesses upon request.
Q5: What is the Minimum Order Quantity (MOQ) for wafer connectors?
For standard pitches and configurations, our MOQ is very flexible to support your prototyping and pilot runs. For SMT components packaged in Tape & Reel (T&R), the MOQ is typically dictated by the quantity per reel (e.g., 500 or 1,000 pieces per reel).
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