What is Wire Stripping and Crimping?

When dealing with wires that one wishes to interconnect, it is important to understand the basics of wire stripping and crimping. Through proper stripping and crimping, one is able to prepare and attach wires together with ease, ensuring that an optimal electrical connection is established and upheld. When dealing with wires that are to be used in an aircraft, it is crucial that the proper tools and methods are utilized for the means of preventing dangerous repercussions. In this blog, we will discuss the basics of such procedures, allowing you to best guarantee optimal conductor connections and wire assemblies.

Wire stripping refers to the removal of the protective layers of a wire, exposing the conductive element underneath. It is important to utilize mid-range quality tools or better, though lower-end tools may be modified before using them for aircraft wire components. The best tools are those that are procured from a trustworthy distributor of electronic components and toolsets, thus one should always vet their sources prior to making a purchasing decision.

For the best stripping tools, one should find a stripper that features a wide range of options, such as those that can be adjusted to accommodate wires of varying dimensions. To strip an aircraft wire, the wires should be placed into a cavity of the tool that is correctly sized. By squeezing the tool, the rear end of the stripper will grip the wire as the stripping dies are clamped around it. By increasing the force of the squeeze, the stripper will cut into the wire, removing the outer length of insulation so that the conductor becomes exposed. Generally, a full strip will require the user to squeeze the handle of the tool until the handles are almost touching. Once the tool mechanism releases the wire automatically, you will have fully exposed the conductor.

Once the wire is successfully stripped, the conductor can then be crimped onto any type of pin or terminal that you require. For aircraft applications in particular, D-Sub machined pins are useful, and they can be crimped onto a conductor with the use of a Mil-Spec certified crimper or another tool variation. For installation, the tool is used to first place a pin onto the stripped wire, and a window may be provided to allow the installer to see if there is an optimal distance between the pin and conductor. Once the pin is ready, it is inserted into the open cavity of the crimper face. The crimper should serve to guarantee proper depth placement, and the tool will need to be squeezed together until it automatically releases. Generally, a pin that was crimped correctly should exhibit around four to eight indentations around the pin’s circumference. Alongside such examples, there are other various crimping tools, including those such as the standard ratcheting terminal crimper, Molex type crimper, coax connectors, and more. Once you have narrowed down the exact tools and components that you require to crimp the wires that you are working with, take advantage of a trustworthy distributor such as Aerospace Store to easily begin procuring every part that you desire.

Aerospace Store is a website owned and operated by ASAP Semiconductor, and we are your sourcing solution for all of the equipment you need to optimally carry out your operations. With AS9120B, ISO 9001:2015, and FAA AC 00-56B certification and accreditation, we exceed industry standards in terms of quality control to guarantee products that you can steadily depend on with ease. Explore our massive set of offerings at your leisure, and our team of industry experts is always on standby to assist you through the purchasing process however necessary. Send us a completed RFQ form at your earliest convenience and experience the future of part procurement with Aerospace store.


March 31, 2022

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