High terminal-to-terminal insertion efforts have created the need for improving the design of high density interconnection systems. To meet this challenge with a reduced design time schedule systematic analytical work is required.As a result of analytical research, a unique three-phase evaluation procedure is presented. Phase I determines the possible terminal deformations; Phase II estimates the ultimate insertion effort. And finally, Phase III analysis computes the variances in such a force and helps to select the design parameters for an optimum insertion effort with minimum uncertainties.At this stage, it appears imperative that the suggested three-phase analytical concept be accomplished even before any tooling is initiated. The final evaluation, however, must be based on testing of actual parts.