Stripping the insulation off wires is an essential task for many electrical projects and repairs. Choosing the right tool for the job makes the process quicker, easier and safer. There are a variety of wire stripping tools available, from basic mechanical strippers to more advanced tools that use blades, notches or heated elements. Selecting the optimal wire stripper depends on factors like the wire size, type and amount of insulation to remove. This article will examine the most effective tools for stripping different gauges and types of wire.
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Key Factors in Choosing a Wire Stripper
When selecting a wire stripping tool, there are a few key considerations:
Wire gauge – The thickness of the wire determines the size of the tool required. Strippers are designed for specific wire gauges or ranges. Using a stripper meant for larger wires on small gauges can damage the wire.
Insulation type – Common insulation types include plastic, rubber, varnish and Teflon. Some tools work better on certain insulation types. For example, thermal strippers are ideal for Teflon coated wires.
Insulation thickness – Thicker insulation requires a more powerful stripping mechanism. Wire strippers have specified capacities for insulation thickness.
Solid vs. stranded wire – Solid core wiring has a single conductor while stranded uses multiple fine strands. Some tools better suit solid core and some work better for stranded wires.
Amount of insulation to remove – For connectors you may need to strip just the end, while joining wires can require removing insulation along the length. Choose a stripper designed for your application.
Frequency of use – Those who regularly strip wires may want a heavy-duty tool while hobbyists can opt for a basic inexpensive model.
Mechanical Wire Strippers
Mechanical wire strippers are manually operated tools that use blade and notch designs to slice through the insulation. They represent the most common and affordable type of wire stripper.
Types of Mechanical Strippers
Simple Notch Tool
The basic mechanical stripper has one or more notches of specific sizes designed to match various gauge wires. The notches have a circular opening slightly smaller than the conductor diameter. To use this type of tool, the wire is inserted in the appropriate notch and the handles squeezed. This pierces the insulation so it can be pulled off with pliers.
Blade Slot Stripper
More advanced mechanical strippers have circular blade slots lined up next to notches. The wire is inserted into the notch, lining up the insulation with the blade slot. As the handles are pressed, the sharp circular blade slices through the insulation.
Self-Adjusting Wire Stripper
This type has a spring-loaded mechanism that automatically adjusts to the wire size when the handles are squeezed. No gauge selection is required. The auto-adjusting design helps adapt to off-size wires.
Multi-Gauge Wire Stripper
These have multiple notches and/or blade slots in a single tool to accommodate many wire gauges. This allows stripping everything from fine electronics wiring to heavy cable without switching tools.
Insulation Length Stop Strippers
These include length stops that control how much insulation is removed. Length stops ensure consistent stripping for wires being terminated with connectors.
Jacket Ripper Strippers
Designed for tough outer jackets like on armored cable, these have special blades to cleanly rip through the outer jacket to access the inner conductors.
Advantages of Mechanical Strippers
– Inexpensive pricing starting under $10
– Simple manual operation
– Compact size for easy storage
– Strips most common wire insulation types
– Various styles for different applications
– Durable construction for repeated use
– Multiple gauge capacities in one tool
– Allows precise control over strip length
– Suitable for solid or stranded wires
Disadvantages of Mechanical Strippers
– Not as speedy as power stripper tools
– Requires proper gauge selection and adjustment
– Can damage or nick wire if wrong size selected
– Not designed for high-volume professional use
– Requires periodic blade sharpening or replacement
– May crush soft stranded wires if not used properly
– Limited insulation thickness capacity
– Can be tricky learning how to position and turn the wire
Automatic/Power Wire Strippers
For those stripping large batches of wires, automatic or power wire stripping tools can save significant time and effort. These make the process much quicker but cost substantially more than basic mechanical strippers.
Types of Powered Wire Strippers
Electric Wire Strippers
These operate like mechanical strippers but an electric motor drives the blade instead of manual force. Often programmable, electric models can rapidly strip many wires to a precise length.
Rotary Strippers
Rotary tools use small high speed motors and grinding wheels to sand away insulation. No blades are involved. Variable speed triggers offer precise control.
Thermal Wire Strippers
Heating elements are used to melt the insulation so it can be easily wiped or pulled off. Thermal tools quickly strip tough coverings like Teflon. Some have temperature controls.
Ultrasonic Wire Strippers
These utilize ultrasonic frequency vibrations focused on the insulation. The rapid vibrations break down the material, allowing the insulation to be removed. Quick and effective on tough coatings.
Laser Wire Strippers
Lasers ablate (vaporize) insulation without contacting the wire. This avoids nicks and preserves wire integrity. Lasers allow ultra-precise stripping. Expensive but used for applications like medical devices.
Advantages of Powered Strippers
– Much faster stripping speed than manual tools
– Can quickly strip wires in mass production settings
– Programmable for consistency and precision
– Cleanly strips tough insulation like Teflon
– Minimal wire damage risk since no blades
– Easy to use – reduced hand fatigue
– High-end models can integrate with automation
– Extended heavy duty motor life
– Lasers provide ultra-accurate strip depths
Disadvantages of Powered Strippers
– Substantially higher cost – from $50 up to $500+
– Electric models can still nick wires if not used properly
– Rotary tools require smoother operation to prevent wire damage
– Thermal tools may overheat if not properly controlled
– Power supply required – not as portable
– Higher maintenance and potential repair costs
– Can be overly aggressive on soft wires
– Lasers very expensive and overkill for basic use
Best Wire Strippers for Common Situations
General Home Use
For basic home wiring projects, a simple mechanical wire stripper provides an affordable and easy to use option. Self-adjusting multi-gauge strippers allow quickly adapting to various wire sizes. Built-in cutters are helpful for clipping off stripped ends. The Irwin Vise-Grip Self-Adjusting Wire Stripper handles wires from 10 to 24 AWG and includes cutters for around $15.
Automotive Use
Auto electrical wiring requires stripping many sizes of wire from small sensor cables up to high power cables. Dedicated auto-wire strippers have the range of gauges needed and sometimes include an ignition barrel key to allow stripping wires in tight locations. The OTC 4590 8-in-1 Klein Wire Stripper covers 10 to 20 AWG wire for around $25.
Telecom/Network Cabling
Installing telephony and data cabling uses lots of solid core wire. Specialized telecom wire strippers make quick work of tightly twisted cables with tough jackets. A basic mechanical model like the Platinum Tools 100054C works well for about $20. For frequent crimping and stripping, powered tools like the $170 Labor Saving ES-1000 provide effortless use.
Electronics Use
Precision wire stripping is vital for electronics to prevent damaging thin fragile conductors or copper strands. For hobbyists, the Hakko Professional Quality Wire Stripper offers exceptional control for around $30. In production, programmable motorized strippers easily handle small gauge wires. The Schleuniger Uni-Strip 2300 programmed stripper precisely processes 24-44 AWG wires but costs around $2,300.
Occasional Use
For infrequent jobs, simple mechanical strippers are the most economical choice. Units like the Irwin Vise-Grip Wire Stripper with cutter provide enough performance for occasional use at roughly $10. Paying more for specialty or power strippers is unnecessary for light duty stripping.
How to Use Manual Wire Strippers
While powered strippers are more automated, manual wire strippers require proper technique to safely strip wires without damage. Here is a step-by-step process:
1. Select the appropriate notch or hole for your wire gauge. Ensure it is the right size or slightly larger but not drastically oversized. Oversized holes can damage thin stranded wires.
2. For blade slot strippers, ensure the insulation lines up with the circular cutting blade.
3. Avoid placing excessive downward force which can crush the wire before cutting the insulation.
4. Hold the wire taut in the notch/hole while gently closing the handles until the insulating sheath is cut through. Don’t re-squeeze as this can nick conductors.
5. Rotate the wire 1/4 turn and squeeze again until the insulation cut is complete. For thick insulation, additional rotations may be required.
6. Grab the end of the insulation with pliers and gently pull it free from the cut ends of the wire.
7. For conductors being inserted into connectors, trim off any stray strands so all strands are even.
8. Periodically oil stripper joints and sharpen/replace blades to maintain performance.
Proper blade alignment, controlled pressure, and turning the wire while cutting prevents damaging conductors while efficiently stripping even tough insulation. Patience and practice help ensure great results.
Safety Tips for Wire Stripping
While stripping wires may seem straightforward, following some basic safety practices avoids injuries or problems:
– Wear eye protection – wire bits and insulation fragments can fly off
– Double check wire is fully de-energized to prevent shocks
– Ensure good work area lighting to see the wire clearly
– Hold wires securely so they don’t twist during stripping
– Keep flammables away when stripping large current wires
– Properly grip and control tools to prevent cuts from blades
– Discard nicked wires or those with damaged conductors
– Take care when working with wire in confined spaces
– Maintain tools in good condition for optimal performance
– Use the right size stripper for each wire to prevent damage
– Don’t rush the process – work carefully and methodically
– Confirm no stray strands or insulation remain in connectors
– Avoid stripping near the middle of wire segments when possible
Following basic precautions makes wire stripping fast, easy and hazard free. Rushing through the process or using the wrong tools increases the risks. Slow down, use the proper equipment and keep your eyes open.
Common Mistakes to Avoid
While wire stripping itself is straightforward, several common mistakes occur. Being aware of these issues allows successfully avoiding them:
– Using the wrong size stripper – Ensure the tool matches the wire gauge.
– Cutting too deep – Adjust pressure to only cut insulation, not the conductor.
– Pulling too hard – Gently pull insulation off, don’t tear wires apart.
– Stripping in the middle – Start stripping at the end, not the middle of a wire segment.
– Twisting while pulling – Keep wires straight to minimize copper strand damage.
– Rushing the job – Work carefully, don’t rush through and make mistakes.
– Choosing cheap low-quality tools – Invest in decent strippers suited for your task.
– Failing to sharpen blades – Sharp blades cut cleanly without mangling wires.
– Using damaged tools – Replace worn or defective strippers.
– Skipping safety gear – Always wear eye protection when stripping.
– Working on live wires – Ensure electricity is shut off for safety.
– Poor lighting – Ensure strippers and wires are clearly visible.
– Allowing wire strands to splay – Keep conductors neatly together.
Avoiding these common errors results in fast, simple and safe wire stripping. Patience and care pays off in the smooth, rapid removal of insulation without wire damage.
Conclusion
Selecting the right wire stripper and using proper technique makes insulation removal quick and easy. For most homeowners, an inexpensive mechanical stripper provides a good balance of affordability and performance for occasional jobs. Those stripping many wires daily benefit from the speed and convenience of powered rotary, thermal or electric strippers despite the higher costs. With the right tool for the job and controlled handling, wires are stripped to perfection in no time. Whether using simple mechanical models or high-tech power strippers, following basic safety precautions and avoiding common mistakes results in fast, effective wire stripping.