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EMS handbook

2. Process preparation: cut, strip, prep

Highly reliable electrical terminations require precise initial wire preparation. Microscopic nicks in copper conductor strands or uneven insulation stripping compromise the mechanical integrity and electrical resistance of the final crimp.

This chapter details the precision mechanics of cutting, stripping, and tinning operations. Calibration standards for automated processing equipment are outlined to ensure every wire is prepared exactly to the connector manufacturer’s specifications.

  • 2.1 Wire preparation: single conductor processing

    Wire preparation is the initial foundation of any successful harness manufacturing process. Process errors unintentionally introduced at this stage—such as dimensionally incorrect cut lengths, nicked...

  • 2.2 Complex cable preparation

    Processing complex cables requires an engineering focus that goes beyond simple wire connectivity to maintaining strict geometric integrity. For highly sensitive coaxial, multi-layer shielded, and den...

  • 2.3 Tooling and machine capability

    High-speed automated wire processing machines serve as the foundation of any modern harness manufacturing facility, capable of producing thousands of stripped leads per hour. However, running extremel...