Wire cutting and stripping to length and tolerance
Wire cutting and stripping is the first operation of any assembly in cable and wire processing, and the one that determines whether the rest fits: the conductor comes out at the length set by the dimension and with the end prepared for what comes next. A cut outside tolerance or a strip that damages strands is not detected at assembly but months later. It is carried out by a manufacturer in the network; we define the requirement with you and check the batch received.
What it involves
What wire cutting and stripping includes
Wire cutting and stripping is the initial preparation of the conductor: the cut fixes its length and the stripping removes the insulation needed at one or both ends, according to the subsequent operation and the project specification. When the work is on the outer jacket of a multicore cable, the trade also speaks of sheath stripping or de-sheathing, and in practice the terms coexist. What matters is not the name but repeatability: that unit number two hundred comes out with the same dimension and the same strip length as the first, and with the strands intact.
- Cut length according to the dimension and tolerance on the drawing
- Strip length suited to the subsequent operation
- Insulation removed without cutting or marking the strands
- Preparation of one or both ends when the project requires it
Process control
Verifiable points of wire cutting and stripping
The acceptance criterion is agreed in writing before the order and depends on the part number, the cable construction and the assigned manufacturer.
- Acceptance criterion recorded before the order is launched
- Sample validated when the part number is new or has changed
- Dimensional check on the material received
- Consistency throughout the batch, not only in the first units
- Different requirement for each end when they are not the same
- What is done if a unit falls outside the agreed margin
How this process is coordinated
How wire cutting and stripping is coordinated
Our role is to translate your specification into a requirement that the manufacturer can repeat and that we can check on receipt of the material.
We receive the specification
Dimension, tolerance, cable construction and intended operation for each end.
We coordinate with the manufacturer
We select from the network the manufacturer with the means suited to the type of cable and the volume, and pass the requirement on in writing.
We validate a sample where appropriate
On a sample, the dimension and the condition of the end are checked before the complete batch is produced.
We check the batch received
Dimensional check on the material received according to the agreed criterion, before delivering it or moving on to the next operation.
What conditions the result
Variables that condition wire cutting and stripping
These four variables are settled in the quote; improvising them is the usual cause of irregular assemblies.
Dimension and tolerance
The total length of the conductor and the admissible margin, which depends on whether the assembly is guided or has slack. Both are taken from the drawing or the specification; they are not assumed.
Type of conductor
The cross-section, the number of strands and the type of insulation condition the tool and the stripping setting. On multicore cable it must also be decided what to do with the outer jacket.
Subsequent process
The strip length is defined by what comes after — crimping, soldering, insertion or direct connection — and not the other way round. If the next operation changes, the preparation changes.
Batch control
Dimensional check criterion agreed to verify that the batch stays within the margin, and what to do if any unit falls outside it.
Related information
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What this process actually covers
Wire cutting and stripping is carried out by manufacturers in our network selected for each project; Justicia Marin defines the requirement with you, coordinates the supply and verifies the batch received. We have no workshop, machinery or laboratory of our own, and we issue no certifications: certificates are those of the manufacturer or supplier that carries out the process. The specific means available and the level of control that can be achieved are confirmed in writing in the quote before the order.
Questions about the process
Wire cutting and stripping: frequently asked questions
- What is the difference between stripping a wire and removing the outer jacket?
- Wire stripping removes the insulation from a single conductor, exposing the copper for crimping, soldering or connecting. De-sheathing removes the outer jacket of a multicore cable, so that the individual conductors become accessible. In many projects both happen: first the jacket is removed, then the conductors are stripped. Both lengths are fixed per end in the specification.
- How accurately can a cable be cut to length?
- That depends on the cable type, the length and the means of the manufacturer. The tolerance comes from your drawing and is confirmed before the order by the manufacturer that carries out the operation. In the quote we record which tolerance is achievable and how it is checked on the batch received, so wire cutting and stripping stays within what you agreed.
- Why is a damaged copper strand a problem?
- Cut or scratched strands reduce the useful cross-section and the mechanical strength, especially under vibration. This is often not visible at assembly. Acceptance criteria, for example from IPC/WHMA-A-620, are agreed before the order and checked by the manufacturer on sample and batch.
- Do you also supply only cut and stripped wires?
- Yes, if loose prepared wires make sense for your own assembly. Usually, however, cutting and stripping is the first step of a complete cable assembly or wire harness, followed by crimping, marking and checking. We discuss which scope brings the most benefit for your project and record it in writing.
- Who carries out the cutting and stripping?
- A manufacturer that we select based on cable type, cross-section and volume. Justicia Marin fixes the requirement with you, passes it on in writing, coordinates the sample and checks the dimensions on the batch received. We have no workshop or machines of our own.
- Which data do you need?
- The total length and tolerance, the strip length per end, the cross-section, number of strands and type of insulation, for multicore cable the de-sheathing length, the next operation per end, the quantity and the check criterion wanted. With a drawing or sample we can move fastest.
- What happens if a batch falls outside the margin?
- The arrangements are fixed in advance: sorting, replacement or return. We report the deviation to the manufacturer, agree the solution and make sure the cause is recorded, so that the next batch falls within the agreed criterion again and you do not have to sort it yourself.
Do you need conductors prepared to length?
Send us dimensions and conductor type.
With the dimension, the tolerance and the envisaged terminal we can prepare a quote and propose the appropriate dimensional check.
What you can send us
- Bill of materials or part numbers (Excel, PDF or text)
- Drawing or schematic for custom assemblies (PDF, DXF or similar)
- Estimated quantity and expected repeat orders
- Your priority: competitive price, certification or lead time
- Required standards or documentation
- Target delivery date
Tell us what you need to buy
We reply within 1 working day.