Connectorization and terminal attachment is done using manual tools supplemented by semi-automatic and automatic crimping and wire stripping and routing equipment.

Value added wire processing usually encompasses measuring, cutting, stripping, and terminating. Each of these processes can be done manually or automated. The choice depends on factors such as volume, type of wire, and customers’ specifications or print requirements. Wire processing can take place using manual, semi-automatic or automatic equipment. Manual processing uses specialized hand tools and techniques. Manual processing can be more cost effective for first articles, prototypes or low volume applications where investing in automated tooling or equipment are not practical.

Semi-Automatic processing uses hand controls to adjust strip length and internal wire stops. Rotary blades and V-blades or specific die-type blades can be used for stripping insulation. There are other methods of stripping insulation called abrasion (fiberglass or steel brushes) and UV laser stripping. Semi-Automatic processing makes sense at a certain volume level and if there is wide variety of wire sizes.

Some of the more typical wire stripping and insulation removal techniques have been automated at dataCon. These include axial slitting; stripping with a partial or full slug pull-off; and inner conductor stripping and forming (removing incremental pieces of insulation) also known as window stripping. Usually the customer specifies the insulated wire type and interconnect application, then dataCon can help determine appropriate wire processing, stripping and termination methods.