MiniSeal High-Performance Crimp Splices

Applications

High-performance crimp splices deliver long-term electrical integrity and environmental sealing in the most challenging aerospace and defense applications. Each splice combines a plated copper crimp barrel, a melt-flow insert, and a transparent heat-shrink sleeve that shrinks around the joint to lock out hydraulic oils, jet fuel, lubricants, and moisture while providing built-in strain relief. Three purpose-built series—parallel (stub), in-line (butt), and a 200 °C high-temperature variant—give engineers the flexibility to match space, routing, and thermal requirements without sacrificing reliability or weight.

Series Overview 

• Stub (parallel) splice: multiple conductors enter from one side; ideal for sensor pigtails, jumper leads, and branch connections in tight spaces. 

• Butt (in-line) splice: conductors enter from opposite sides for end-to-end repairs while maintaining harness profile and routing. 

• High-temperature butt splice: engineered for continuous operation up to 200 °C in engine bays and other extreme-temperature zones.

Characteristics

• Ultra-compact, lightweight construction minimize sharness size and mass 

• One-step crimp-and-heat process speeds installation and lowers overall cost 

• Immersion-resistant seal prevents liquid ingress and subsequent corrosion 

• Transparent sleeve enables instant visual inspection of the crimp joint 

• Integrated strain relief withstands vibration and mechanical stress across aircraft, rotorcraft, and defense platforms

Notes: 

• Select the splice style—stub, butt, or high-temperature butt—based on circuit layout and service temperature. 

• Choose barrel plating: tin for tin or silver-plated conductors; nickel for nickel-plated conductors or applications above 150 °C. 

• Calculate total wire cross-section (CMA or mm²) and use color coding to pick the correct barrel size. 

• Verify that each wire’s insulation fits the sealing-sleeve openings; place no more than two wires in any sleeve hole to maintain seal integrity. 

• Detailed sizing tables, CMA worksheets, and part-number references are available from our technical support team.