dupont - dwilson2547/wiki_demo GitHub Wiki

DuPont Connectors

DuPont connectors are a family of low-cost, versatile electrical connectors commonly used in electronics prototyping, hobbyist projects, and low-current applications. Originally developed by DuPont (now part of TE Connectivity), these connectors are characterized by their 0.1" (2.54mm) pitch spacing and simple friction-fit connection mechanism.

Overview

DuPont connectors feature:

  • 2.54mm (0.1") pitch spacing (compatible with standard breadboards)
  • Simple friction-fit mating mechanism
  • No locking mechanism (relies on friction)
  • Low-cost construction
  • Easy field assembly
  • Wide variety of housing configurations
  • Operating temperature: -55°C to +105°C
  • Voltage rating: Up to 250V AC/DC
  • Current rating: 3A per contact (depending on wire gauge)

Connector Types

Standard DuPont Series

The most common type, featuring plastic housings with friction-fit contacts.

Jumper Wires

Pre-assembled wire-to-wire connections with DuPont terminals.

Pin Headers

Male pin strips designed to mate with DuPont housings.

Socket Headers

Female socket strips, often used on PCBs.

Connector Specifications Chart

Housing Type Pin Count Pitch Housing Dimensions (L×W×H mm) Wire Gauge Current Rating Common Part Numbers
Single Row Housings
Female Housing 1 2.54mm 8.0×2.5×8.5 28-18 AWG 3A 640456-1
Female Housing 2 2.54mm 10.5×2.5×8.5 28-18 AWG 3A 640456-2
Female Housing 3 2.54mm 13.0×2.5×8.5 28-18 AWG 3A 640456-3
Female Housing 4 2.54mm 15.5×2.5×8.5 28-18 AWG 3A 640456-4
Female Housing 5 2.54mm 18.0×2.5×8.5 28-18 AWG 3A 640456-5
Female Housing 6 2.54mm 20.5×2.5×8.5 28-18 AWG 3A 640456-6
Female Housing 7 2.54mm 23.0×2.5×8.5 28-18 AWG 3A 640456-7
Female Housing 8 2.54mm 25.5×2.5×8.5 28-18 AWG 3A 640456-8
Female Housing 9 2.54mm 28.0×2.5×8.5 28-18 AWG 3A 640456-9
Female Housing 10 2.54mm 30.5×2.5×8.5 28-18 AWG 3A 640456-10
Female Housing 12 2.54mm 35.5×2.5×8.5 28-18 AWG 3A 640456-12
Female Housing 15 2.54mm 43.0×2.5×8.5 28-18 AWG 3A 640456-15
Female Housing 20 2.54mm 55.5×2.5×8.5 28-18 AWG 3A 640456-20
Dual Row Housings
Female Housing 2×2 (4) 2.54mm 10.5×5.0×8.5 28-18 AWG 3A 640456-2x2
Female Housing 2×3 (6) 2.54mm 13.0×5.0×8.5 28-18 AWG 3A 640456-2x3
Female Housing 2×4 (8) 2.54mm 15.5×5.0×8.5 28-18 AWG 3A 640456-2x4
Female Housing 2×5 (10) 2.54mm 18.0×5.0×8.5 28-18 AWG 3A 640456-2x5
Female Housing 2×6 (12) 2.54mm 20.5×5.0×8.5 28-18 AWG 3A 640456-2x6
Female Housing 2×7 (14) 2.54mm 23.0×5.0×8.5 28-18 AWG 3A 640456-2x7
Female Housing 2×8 (16) 2.54mm 25.5×5.0×8.5 28-18 AWG 3A 640456-2x8
Female Housing 2×10 (20) 2.54mm 30.5×5.0×8.5 28-18 AWG 3A 640456-2x10
Pin Headers (Male)
Pin Header 1×40 2.54mm 101.6×2.5×8.5 - 3A Break-away strips
Pin Header 2×40 2.54mm 101.6×5.0×8.5 - 3A Break-away strips

Pin Layout Diagrams

Single Row Configurations

1-Pin

1
o

2-Pin

1  2
o  o

3-Pin

1  2  3
o  o  o

4-Pin

1  2  3  4
o  o  o  o

5-Pin

1  2  3  4  5
o  o  o  o  o

6-Pin

1  2  3  4  5  6
o  o  o  o  o  o

8-Pin

1  2  3  4  5  6  7  8
o  o  o  o  o  o  o  o

10-Pin

1  2  3  4  5  6  7  8  9  10
o  o  o  o  o  o  o  o  o  o

Dual Row Configurations

2×2 (4-Pin)

1  2
o  o
o  o
3  4

2×3 (6-Pin)

1  2  3
o  o  o
o  o  o
4  5  6

2×4 (8-Pin)

1  2  3  4
o  o  o  o
o  o  o  o
5  6  7  8

2×5 (10-Pin)

1  2  3  4  5
o  o  o  o  o
o  o  o  o  o
6  7  8  9  10

2×8 (16-Pin)

1  2  3  4  5  6  7  8
o  o  o  o  o  o  o  o
o  o  o  o  o  o  o  o
9  10 11 12 13 14 15 16

Contact Specifications

Contact Type Material Plating Wire Gauge Crimp Tool Part Number
Female Terminal Phosphor Bronze Tin 28-18 AWG Standard crimp 640445-1
Female Terminal Phosphor Bronze Gold 28-18 AWG Standard crimp 640445-1 (Gold)
Male Pin Brass Tin 28-18 AWG Standard crimp 640441-1
Male Pin Brass Gold 28-18 AWG Standard crimp 640441-1 (Gold)

Jumper Wire Types

Type Description Length Options Common Uses
Male-to-Male Pin on both ends 10cm, 20cm, 30cm Breadboard connections
Female-to-Female Socket on both ends 10cm, 20cm, 30cm Board-to-board connections
Male-to-Female Pin to socket 10cm, 20cm, 30cm Board-to-breadboard

Color Coding Standards

Standard Wire Colors

  • Red: Power/VCC (+3.3V, +5V, +12V)
  • Black: Ground/GND
  • Yellow: Data/Signal lines
  • White: Data/Signal lines
  • Blue: Data/Signal lines
  • Green: Data/Signal lines
  • Orange: Clock signals
  • Purple: Control signals

Assembly Instructions

Crimping Female Terminals

  1. Strip wire 2-3mm from end
  2. Insert wire into crimp terminal
  3. Crimp using appropriate tool (or needle-nose pliers)
  4. Ensure good mechanical and electrical connection
  5. Insert terminal into housing until it clicks

Housing Assembly

  1. Insert crimped terminals into housing
  2. Ensure proper orientation (key tab alignment)
  3. Push until terminal locks in place
  4. Verify terminals cannot be pulled out
  5. Check pin 1 orientation

Pin Header Installation

  1. Insert pin header through PCB holes
  2. Ensure proper alignment and seating
  3. Solder all pins from component side
  4. Trim excess pin length if needed

Common Applications

Electronics Prototyping

  • Breadboard connections
  • Arduino/Raspberry Pi projects
  • Sensor interfacing
  • Development board connections

Hobby Electronics

  • LED strips and modules
  • Servo motor connections
  • Switch and button interfaces
  • Display connections (LCD, OLED)

Educational Projects

  • Learning electronics basics
  • STEM education kits
  • Science fair projects
  • Robotics clubs

Low-Power Devices

  • IoT sensor nodes
  • Battery-powered projects
  • Small embedded systems
  • Wearable electronics

Advantages and Limitations

Advantages

  • Low cost and widely available
  • Easy to assemble without special tools
  • Compatible with standard 0.1" pitch components
  • Variety of configurations available
  • Suitable for prototyping and temporary connections
  • No special crimping tools required (can use pliers)

Limitations

  • No locking mechanism (connections can come loose)
  • Limited current capacity (3A maximum)
  • Not suitable for high-vibration environments
  • No environmental sealing
  • Contact resistance can increase over time
  • Not recommended for production applications

Troubleshooting

Common Issues

  • Loose connections: Ensure terminals are fully inserted and crimped properly
  • Intermittent contact: Check for oxidation or bent pins
  • Wrong pin assignment: Verify pin 1 orientation and numbering
  • High resistance: Clean contacts with isopropyl alcohol

Testing

  • Use multimeter for continuity testing
  • Check voltage drops across connections
  • Verify proper crimping with gentle pull test
  • Inspect for bent or damaged pins

Alternatives

Higher Quality Options

  • JST Connectors: Locking mechanism, better reliability
  • Molex KK Series: More robust construction
  • Hirose DF13: Micro-pitch for compact applications

Similar Pitch Connectors

  • JST XH (2.5mm pitch): Slightly smaller spacing
  • JST PH (2.0mm pitch): Compact option
  • Molex PicoBlade (1.25mm pitch): Ultra-miniature

Storage and Handling

Best Practices

  • Store in anti-static bags when possible
  • Keep housings and terminals separated until use
  • Avoid bending pins excessively
  • Protect contacts from contamination
  • Use proper orientation when mating/unmating

Inventory Management

  • Color-code wire sets for easy identification
  • Keep common sizes (2, 3, 4, 5-pin) readily available
  • Maintain stock of both male and female jumper wires
  • Store in organized compartmented boxes
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