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Use 0.1" headers for quick prototypes, low current, and easy rework. Choose a locking wire-to-board system when you need secure retention, better polarity protection, or higher current capacity. If the device moves, vibrates, or ships to customers, latching and keyed housings are worth it.
For hand assembly, 0.1" is the most forgiving. You can step down to about 0.079" or 0.05" if space is tight, but use a fine tip, good flux, magnification, and a steady hand. If you’re new to soldering, staying at 0.1" makes success much easier.
No, but they help. Gold resists oxidation and keeps contact resistance low, especially for low-level signals and high mating cycles. For power connectors in clean environments with few re-mates, tin plating is often sufficient and more cost-effective.
A good starting point is about 700°F with leaded solder and an iron that recovers heat quickly. Adjust slightly up or down based on joint size and tip geometry. Keep contact time short, use flux, and avoid pressing hard so you don’t lift pads or deform plastic.
Add strain relief wherever a cable flexes: heat-shrink over crimps, cable glands at panel entries, and zip-tie anchors inside enclosures. Choose connectors with latches, route wires with gentle curves, and leave a small service loop so movement doesn’t pull directly on the contacts.