10. Practical Selection Checklist

Use this at work. Adapt to your program; it is a working checklist, not a standard.

Interface definition

• What subsystem boundary is this?
• Internal or external?
• Technician-serviceable or factory-only?
• Must it be disconnected under power?
• How often mated/unmated over service life?
• Is wrong mating dangerous?

Electrical

• Voltage rating + transients/peak checked
• Current per contact at temperature checked
• Bundle/thermal derating applied (use a conservative margin and the manufacturer derating curve)
• Wire gauge compatible with contact barrel
• Signal type identified; high-speed/RF flagged
• Shields/grounds assigned (360° where needed)
• Power and signal segregation considered
• Spare positions added where feasible and justified (and sealed/documented)

Mechanical / environmental

• IP rating verified for the complete assembly
• Mated and unmated (capped) sealing considered
• Vibration/shock requirement and locking matched
• Cable strain relief defined; backshell selected
• Cable jacket OD compatible with gland/clamp
• Wire seal range matches wire OD; unused cavities plugged
• Bend radius and cable exit angle checked
• Panel thickness/cutout checked
• Mating sequence (ground-first) considered for hybrids, where available
• Torque specs identified
• Dust caps / dummy plugs on BOM

Manufacturing

• Crimp contacts and correct crimp tool identified
• Positioner/die and insert/extract tools identified
• Assembly instructions + inspection criteria defined
• Pull-test / continuity test plan defined
• Supplier availability and lead time checked
• Second source / QPL considered

Documentation / configuration control

• Connector, mate, contact, backshell, cap, gasket part numbers
• Pinout table + cable drawing + harness drawing
• ICD entry written
• Key position unique across differing pinouts
• Rev-controlled BOM + labeling scheme

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