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From automotive to medical devices, crimping is a common manufacturing process that spans industries. Two pieces of metal or some other malleable material are compressed together through a process of deformation such as bending.

Typical issues related to crimp operations

  • Missing wires or terminals
  • Missing or soft crimps
  • Missing strands or ears
  • Debris caught in the terminal
  • Double crimps
  • Incorrect wire gage
  • Improper placement



These kinds of crimping defects are often not detected until much later in the assembly process. With any defect, the longer it takes to catch, the more costly it is to address. Sciemetric provides accurate, effective, real-time crimp force monitoring to catch all these defects and more.

Monitor crimping in real-time and avoid destructive pull-tests

Sciemetric’s sigPOD and its digital process signature analysis software delivers the real-time pass-fail feedback and advanced defect detection to find crimp defects quickly.

sigPOD monitors force versus distance and force versus time waveforms during the entire crimping process. This provides a consistent measurement standard for evaluating the quality of the crimping operation.

sigPOD provides a reliable, data-driven and objective means to determine quality of the crimp versus other methods such as manual pull tests.

Crimp sigPOD screen

Download the sigPOD product brochure

Application example: Monitoring crimps that are critical to life

A manufacturer of medical devices needed a reliable means to monitor and verify the crimping operation for wire leads connected to the body of a pacemaker. As a medical device subject to strict regulatory oversight, the manufacturer is under tremendous pressure to ensure zero defects.

Sciemetric deployed a sigPOD system that provided the required reliability to identify defective crimps. The solution eliminated the destructive testing previously used – pull testing of the leads on a batch of pacemakers – and replaced it with a data-derived, objective decision that was more consistent with the requirements for the industry.

Read the application note




Real-world applications of crimp monitoring

Learn more about how our systems have been used to monitor and improve:

Crimping copper terminals onto wires for automotive wire harnesses


Crimping for spool valves with a solution that took less than a day to develop


Rivet quality by analyzing crimp force


Take the utility of your crimp data one step further with QualityWorX

By collecting the results from crimping operations by part and integrating them with data from other processes on the assembly line manufacturers can act more quickly to resolve quality and productivity issues. Explore how our QualityWorX suite of data management and manufacturing analytics software can consolidate crimp part data with all your other production part data to provide a practical and faster way to:

Image of defective parts in a population

  • Identify the root cause of defects or issues affecting throughput
  • Very quickly pinpoint affected parts to avoid a mass recall or stop ship
  • Continuously optimize stations by using the data to set limits, cycle times, etc.
  • Demonstrate conformance for each part

see how QualityWorX  provides better visibility into  part data