HD44 Male to Open Wire Breakout Cable
The PCM-0959 HD44 male to open wire cable is a custom 44-position high-density D-Sub breakout assembly designed for direct integration with terminal blocks, control panels, test fixtures and customer-specific electronic equipment.
The P1 end uses an HD44 male connector with a black insulator, nickel-plated shell and UNC #4-40 locking hardware. The P2 end is supplied as 44 individually identified flying leads with pre-stripped conductor ends for subsequent soldering, terminal connection or installation of customer-selected contacts.
A black UL20276 28 AWG multi-pair shielded cable and an in-line ferrite core are used in the standard construction. The nominal finished cable length is 1.5 m, while cable length, pin assignment, flying-lead preparation and labeling can be customized according to an approved drawing or wire list.
Connector and Termination Configuration
| Configuration Item | Standard Construction |
| P1 Connector | 44-position high-density D-Sub male, commonly described as HD44 male |
| Connector Shell | Nickel-plated metal shell with black insulator |
| Locking Hardware | UNC #4-40 locking screws |
| P2 Termination | 44 color-identified open wires / flying leads |
| Flying-Lead Length | 75 ± 10 mm |
| Pre-Stripped Length | 3 ± 1 mm |
| Internal Product Number | PCM-0959 |
This is an HD44 connector-to-loose-wire assembly rather than a standard pin-to-pin extension cable. The electrical function is established by the approved HD44 pinout and wire assignment, not by the connector shape alone.
Multi-Pair Shielded Cable Construction
| Construction Item | Drawing Specification |
| Cable Standard | UL20276 |
| Conductor Construction | 28 AWG × 25 pairs + AEB |
| Cable Outside Diameter | Approximately 8.0 mm |
| Cable Color | Black |
| Nominal Finished Length | 1500 ± 30 mm |
| Ferrite Core | Approximately 17.5 × 28.5 × 11 mm |
| Ferrite Position | Approximately 50 ± 5 mm from the connector-side reference shown on the drawing |
| Heat-Shrink Tube | 8.0 × 25 mm |
| Compliance | RoHS compliant |
The ferrite core is included as part of the standard construction to support electromagnetic-noise control in the completed installation. Its effectiveness depends on the operating frequency, cable routing, equipment grounding and overall EMC design.
The drawing specifies a 25-pair cable, while 22 pairs are assigned to the 44 HD44 contact positions. The treatment of the remaining internal conductors is not defined by the published wire list and should be confirmed when it is relevant to the application.
Open-Wire End Preparation
The open-wire end is prepared for integration into customer equipment. The standard construction provides approximately 75 mm of separated flying leads, with each conductor pre-stripped by approximately 3 mm.
| Integration Method | Application Consideration |
| Terminal block connection | Confirm conductor preparation, ferrules and terminal acceptance for 28 AWG wire. |
| PCB soldering | Confirm pad spacing, strain relief and conductor identification before installation. |
| Crimp-terminal installation | Select contacts compatible with the conductor and insulation dimensions. |
| Secondary connector assembly | Provide the connector part number, cavity map, strip length and crimp specification. |
| Direct equipment wiring | Verify the complete HD44 pinout, circuit function and grounding arrangement. |
Electrical Inspection Requirements
| Inspection Item | Drawing Requirement |
| Wiring Inspection | 100% open-circuit, short-circuit and miswire test |
| Insulation Resistance | 10 MOhm Min., DC 300 V, 0.01 sec. |
| Contact Resistance | 3 Ohm Max. |
| Dimensional Inspection | Finished length, flying-lead length and pre-stripped length checked against the approved drawing |
| Visual Inspection | Connector, overmold, ferrite core, heat-shrink and wire preparation inspected for workmanship |
Additional continuity records, pinout reports, dielectric testing or customer-defined inspection can be evaluated when specified before production.
Drawing
Frequently Asked Questions
Is this an HD44 pigtail or flying-lead cable?
Yes. HD44 pigtail cable, HD44 flying-lead cable, HD44 to bare wire cable and HD44 to open wire cable are commonly used descriptions for this connector-to-loose-wire construction.
Are all 44 conductors individually identified?
Yes. The standard wire list assigns a specific color to every HD44 contact position from Pin 1 through Pin 44.
Can the pinout be changed?
Yes. A custom HD44 pinout can be manufactured from a customer-approved contact map, equipment drawing or verified cable sample.
Can this replace an existing HD44 cable?
A replacement can be evaluated when the mechanical interface, #4-40 locking arrangement, complete pinout, pair grouping, shield termination, cable length and electrical requirements are available.
Is this sometimes called a DB44 cable?
Some buyers use DB44 as a search term, but HD44 or 44-position high-density D-Sub is the more precise interface description for this three-row connector.
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