Wire Strippers

Choosing the right wire stripper depends on the type of wire the operator is working on, the volume of work and the level of precision required.

Type of wire - Firstly, consider the wire gauge that is being worked on, because it is extremely likely that if the wrong gauge size is used, then the wire stripper blade will nick or weaken the conductor.

Secondly, consider the type of insulation covering the conductor. Standard PVC can be stripped with most manual wire strippers, but tougher materials such as PTFE, Teflon, silicone or military-grade insulation will require a precision wire stripper blade, which will likely have a military specification (Mil-Spec), or use a thermal wire stripper.

Volume of work - A manual wire stripper is cost-effective, accurate and reliable. However, if the wire stripping work is repetitive or is high-volume production work, a cordless or pneumatic stripper will be more efficient, whilst also reducing hand fatigue.

Precision requirements - Wire stripping work that is carried out in aerospace, defence, automotive or rail, often requires wire strippers that meet Mil-Spec, which ensures that specific wire types can be stripped consistently without any damage to the conductor. For example a 45-1774 Custom Stripmaster meets SAE-AS5768 standards and is designed to strip wire types such as 9 Mil Kapton, 13 Mil Kapton, BF Wire, CF Wire, DK Wire, PAN 6411 DP 020, PAN 6411 DP 030 and Pan Type 6423.

When using wire strippers it is key to ensure that safety guidelines are followed to ensure that the operator is protected, as well as future proofing other peoples safety. What do we mean by that?

Operator safety - When using wire strippers, always ensure that electrical power is turned off before stripping any wire because working on live circuits can result in electric shock, burns and serious injury. We recommend using a voltage tester to confirm the circuit is not live before beginning work.

In addition, the operator should wear appropriate personal protective equipment (PPE), such as safety glasses to protect against flying insulation pieces, cut-resistant gloves to protect the hands from getting cut when working with sharp wires, and also work in a well-lit area to enhance visibility.

Future safety - When stripping wire, the gauge selected on the wire stripper must be the same as the gauge of the wire, because a stripping slot that is too small can nick or cut the conductor, and if the stripping slot is too large then the wire stripper may not remove the insulation properly. Both of these instances can create a future failure point, potentially leading to poor connections, dangerous overheating, electrical arcing or short circuits.

To ensure that the stripping blade will strip the wire accurately and effectively, it should be inspected regularly to confirm that it is sharp, clean and aligned. When carrying out the wire stripping work, the operator should avoid twisting or pulling the insulation excessively because this can stretch or break the conductor.

Wire strippers should be maintained because it helps to enhance their tool life, whilst ensuring that they provide accurate stripping. Some tips we have to maintain them includes - 

Regularly inspect the cutting blades and keep them clean - After use, wipe the blades and the tool with a dry cloth to remove insulation debris, dust and any metal particles that could be present, because a build-up of any residue can affect wire stripping performance and accuracy.

It is always recommend to regularly check cutting blades for nicks, dullness or misalignment. Dull blades can damage conductors and require more force to use, which increases the risk of slipping and operator fatigue. Many wire strippers have replaceable blades, but if they don't then consider replacing the tool when performance declines.

Look after the pivot joint - Occasionally apply a small amount of light machine oil to the pivot joint if using manual wire strippers, to keep the mechanism moving smoothly. Pneumatic wire strippers may require periodic oiling of the internal components to keep the tool running smoothly (always check the manufacturers guidelines). Always enure that any excess oil is wiped away to prevent it transferring onto wires.

Storage - Wire strippers should always be stored in a dry, protected location like a tool box, to prevent rust or corrosion.

A military specification (Mil-Spec) wire stripper is a wire stripper that meets extremely tight tolerances set by U.S. military standards, to ensure consistent and repeatable wire stripping results, and are widely used in sectors where precison is key, such as aerospace, automotive, rail and defence.

Mil-spec wire strippers are designed for use on specific wire types to ensure that they remove insulation without nicking, scoring or weakening the conductor.

Some mil-spec wire strippers can also be supplied with certificates, which ensures compliance and traceability requirements are met.

The correct wire stripper should be used with the correct wire gauge to prevent the conductor (which is usually copper or aluminium) from getting nicked. This is because even a small amount of damage can weaken the wire, due to the cross-sectional area being reduced, which increases electrical resistance. An increased electrical resistance can lead to electrical or mechanical failure, which increases overheating and potentially risks a fire hazard.

In addition, damaged conductors are more likely to break and fail under vibration, movement or when they are repeatedly bent, which can happen in regulated industries such as aerospace, rail and automotive, where wiring is exposed to constant motion. 

Automatic wire strippers are designed to adjust to the gauge of wire being stripped automatically, whereas manual wire strippers require the operator to choose the correct stripping blade for the wire gauge being stripped.

Generally it should be considered that manual wire strippers are more accurate, whereas automatic wire strippers enable the operator to strip varied wire sizes quicker, whilst reducing hand fatigue, making them well suited to repetitive or high-volume tasks in manufacturing and production environments.

A thermal wire stripper uses controlled heat to soften the insulation, so that it can be removed cleanly without cutting into the metal conductor, which makes it ideal for use on fine-gauge or delicate wires, where even a small nick from a wire  stripping blade could weaken the conductor. However, thermal wire strippers are also ideal for use when stripping tough or high-performance insulation materials, such as PTFE (Teflon), Kapton and silicone, because these materials can be difficult to strip mechanically and often require excessive force from the operator, which increases the risk of damage to the conductor.

The amount of insulation that should be stripped before crimping a connector onto the end of the wire, depends on the type of connector that is being used, as well as its size. The general rule is to strip only enough insulation so that the bare conductor fits fully inside the terminal barrel, without leaving any exposed wire outside of it.

If too much insulation is stripped and it sits outside of the barrel, then it increases the risk of a short circuit, whereas if too little is stripped, the insulation may get caught inside the crimp area, which could prevent a secure electrical connection.

The operator should always follow the manufacturer's guidelines on how much insulation should be stripped from the wire being worked on, to ensure that a strong mechanical grip can be created when it is crimped, which in turn allows for a low-resistance electrical connection.