That title sums it up pretty well- but to add context, I'm working on a modular system that might end up drawing more than the rated 3A of standard 2.54 straight connectors that we all like so much. If there were a version that was just a bit higher rated, maybe round or blade pins or something I'd probably go with that even though I think I can get away with 3A for now, and yes, I could try to leave a few extra pins to run in parallel, but to future proof the design I'd probably seize the oppportunity if there was one. Relatively low profile is on the agenda too so the present iteration of the 2.54mm plugs are pretty close to ideal with the one exception of current capacity. (if we need a target, lets say 5A or more) Thanks for any ideas!
And what are you planning to connect to these 'header' pins ? a PCB ?
Find high quality headers, not the cheapest crap from AE.
https://www.molex.com/en-us/products/part-detail-pdf/22284040?display=pdf
I'm working on a small modular cnc platform so it will vary, most will be data or low power tasks but sometimes it could be a 40w or more laser or up to a 5a heater. I think I've found what I was hoping for just now in the form of 3.96mm standard connectors. Its the versatility that makes it a bit tricky along with the low profile. I want to spec pins that will still work for the highest draw I can envision. For anyone else looking and not super familiar, that keyword ("3.96mm") in general gets you to 7A capacity.
Look at DIN connectors.
If you only need 5A, how about using 2 pins in parallel for the connections that have that amp requirement and single pins for the ones that don't.
Edit: I see now that you thought of that already.
I think I am going to end up trying that first since I have all those on hand already. It would be better to use the 3.96mm spec but they're slightly harder to accommodate and I'd prefer to not have the snap features/extra width. The main drive here is that I just want one umbilical style plug that has everything on it instead of one for higher power things, then one for data, then one for fan, etc.
So, while the 3.96mm spec is better for me, I'd prefer the "minimalist" form factor of the standard 2.56mm's That is, just a rectangle plug with no tabs or index and a rectangle pin block that I could cut to size if desired. If anyone knows of something like that please let me know! (in other words if we just took your 2.56mm plug kit and clicked "Scale up by ~150%" we'd be perfect!)
I would look for connectors at Mouser, Digikey etc.
I already gave OP a link for 4A ones, probably one can find even better.
Also, if you have a look at beefier RC servos, they usually have 2.54 headers.. and high amps..
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