Wire Cutting & Stripping Services
Wire Cutting & Stripping Are
Foundational Steps in Wire Harness Manufacturing
Wire Cutting and Wire Stripping are
fundamental front-end processes in wire processing and wire harness assembly.
Before wires proceed to terminal crimping,
soldering, or connector assembly, they must first be cut to the specified
length and stripped according to customer drawings and product requirements. Wire
length, strip dimensions, and conductor integrity directly affect the
consistency and reliability of downstream termination and harness assembly.
IPC/WHMA-A-620 also covers cable / wire
length measurement, conductor strand damage, stripping, and related inspection
requirements as important parts of wire harness manufacturing.
SyncTronics Technology can evaluate wire
length, AWG, insulation material, single-end or double-end stripping, strip
length, and downstream termination conditions based on customer drawings,
samples, wire / cable specifications, and assembly requirements.
Wire Cutting Is More Than Simply Cutting
a Wire to Length
For an electronic wire harness, wire
cutting involves more than the finished length. Length tolerance, termination
allowance, and downstream assembly requirements must also be considered
according to the product drawing.
For multi-wire or multi-branch harnesses,
incorrect wire or branch lengths may affect terminal position, connector
assembly, and the final harness configuration.
Custom wire cutting typically requires
confirmation of:
・Wire / Cable type
・AWG or conductor size
・Finished wire length
・Length tolerance
・Single-end or double-end processing requirements
・Required allowance for termination
・Downstream terminal and connector assembly method
・Branch length and cable exit requirements, if specified
Wire cutting dimensions should follow
the customer drawing and final harness specification rather than being
determined only by the distance between two connection points.
For NPI prototyping, low-volume high-mix
production, or special-length projects, sample builds can be used to confirm
wire length and downstream assembly conditions before final production
specifications are established.
The Key to Wire Stripping Is Strip
Length & Conductor Integrity
The purpose of Wire Stripping is to remove
a specified length of insulation and expose the conductor for terminal
crimping, soldering, or another termination process.
In addition to Strip Length, the insulation
cut and conductor condition must also be controlled.
If stripping causes conductor nicks, cuts,
or broken strands, downstream termination quality may be affected. Strip Length
that is too long or too short may also prevent the conductor and insulation
from being positioned correctly within the terminal or termination area.
Different terminals and wire sizes may
require different stripping dimensions. Connector and terminal manufacturer
application specifications commonly define specific Strip Length requirements
for different wire ranges and require the stripping process to avoid damaging
the conductor.
Therefore, a single Strip Length should
not be applied to all wires. The stripping dimensions should be confirmed
according to the wire specification, insulation construction, terminal
manufacturer requirements, and customer drawing.
AWG, Wire Construction & Downstream
Termination Should Be Confirmed Together
AWG represents conductor size, but its
impact extends beyond the wire itself. It is also related to the applicable
range of the terminal and connector used in the final assembly.
When evaluating Wire Cutting and Stripping,
it is important to confirm not only how long the wire needs to be, but also:
・AWG
・Conductor construction
・Insulation outer diameter
・Terminal wire range
・Connector / Housing specification
・Downstream crimping or soldering method
Terminals typically have specified wire
size and insulation diameter ranges, so the wire, terminal, and processing
dimensions should be evaluated together according to the final product
requirements.
For additional information on wire size,
resistance, voltage drop, and cable selection, refer to 「AWG
and Cable Selection Explained: Wire Size, Cross-Sectional Area, Resistance,
Voltage Drop, and Current-Carrying Capacity｜Technology Year: 2026 (Latest
Revision)」。
Wire Cutting & Stripping Lead into
the Next Wire Harness Processes
Wire Cutting and Stripping are front-end
preparation processes. Once completed, the wire can proceed to terminal
crimping, termination, connector assembly, and final harness assembly.
A typical process flow can be understood
as:
Wire Cutting
→ Wire Stripping
→ Terminal Crimping / Termination
→ Connector Assembly
→ Wire Harness Assembly
→ Inspection
For a broader overview of wire processing,
refer to 「What
Are the Steps in Wire Processing? Complete Guide to the Manufacturing Process」。
If the project requires terminal crimping
or other termination processes after cutting and stripping, refer to 「Terminal
Crimping & Termination」。
Actual Wire Harness Products &
Processing Applications
Wire Cutting and Stripping are widely used
in electronic wire harnesses, control wiring, and custom Cable Assemblies.
Different finished products may require different front-end processing
conditions depending on the connector, terminal, wire gauge, cable length, and
harness structure.
SyncTronics' 「MX3.0 Wiring Harness」 can serve as a
practical example of a general electronic wire harness. Actual production
requires the wire to be prepared according to the connector, pin configuration,
wire specification, and finished harness length.
Another example, 「D-Sub
37 Pin to 4 D-Sub 9 Pin UART Cable Adapter」, uses a one-to-multiple-branch
structure. This type of assembly may involve multiple branch lengths, pin
definitions, wire specifications, shielding, and locking requirements. It
illustrates why each wire and branch must be prepared according to the final
harness structure.
Although the final structures of these
products are different, Wire Cutting and Wire Stripping must always follow the
downstream terminal, connector, and finished harness requirements.
For more electronic wire harnesses, cable
harnesses, and Cable Assembly products, refer to 「CABLE
ASSEMBLY & WIRE HARNESS」。
NPI & Low-Volume High-Mix Projects
Can Use Samples to Confirm Processing Dimensions
During new product development or
low-volume high-mix projects, wire length, Strip Length, terminal, or connector
specifications may still require confirmation during the prototype stage.
The NPI process can therefore use customer
drawings and existing specifications to build samples and confirm:
Wire Length
→ Strip Length
→ Terminal / Connector
→ Downstream Assembly
→ Finished Harness
If the specification changes after sample
verification, the production documentation should be updated accordingly to
prevent outdated dimensions from being used in later processing.
Recommended Information for Wire Cutting
& Stripping RFQs
To improve specification review and
quotation efficiency, customers are encouraged to provide:
・Product drawing or physical sample
・Wire / Cable brand, part number, or specification
・AWG or conductor size
・Insulation material and outer diameter
・Finished wire length and tolerance
・Single-end / double-end stripping requirements
・Strip Length
・Terminal part number or specification
・Connector / Housing information
・Downstream crimping, soldering, or assembly method
・NPI prototype quantity and estimated production quantity
・Other specified processing or acceptance requirements
Need Wire Cutting & Stripping
Services?
If your product requires Wire Cutting, Wire
Stripping, electronic wire processing, or custom Wire Harness manufacturing,
please provide your drawings, samples, wire specifications, and estimated
quantities through 「Contact Us」。