Wire Cutting and Stripping: An important process of wire harness manufacturing

We’ll look at the various wire-cutting and stripping methods in this article.

There is a growing need for cable assembly manufacturers, causing them to play a significant part in every electronic and electrical product.

Proper Cutting and stripping wire is a prerequisite for cable manufacturing.

After the popular service, you can assemble and pack wire harnesses and cables. 

What Is Cut And Stripped Wire?

In the context of electrical wiring, “cut and stripped” refers to a wire that has been shortened and has had its insulation removed.

A cut and stripped wire is stored in its original packaging until it is ready to be assembled. 

The unprotected metal conductor is sought for subsequent circuitry applications in electrical and electronic applications, connecting other components or devices at exact lengths. 

Stripped electrical cable wires

Stripped electrical cable wires

Types of Wire Cutting and Stripping

Three types of wire cutting and stripping are distinct regarding the sheath and their specific advantages.

Full wire cutting and stripping

Full Cutting and stripping a wire means removing all the insulation covering the wire’s metal conductor before cutting it.

This technique requires cutting and removing insulation and jacket to reveal the central conductor.

You need full wire cutting and striping when the full cable has to be seen for termination or connection.

Blunt wire cutting and stripping

Blunt wire cutting and stripping is the practice of severing a wire without first removing its insulation.

With this method, you snip the cable to the right length, and you’re done. If your team uses this method correctly, you will save time and effort.

There is a significant difference between the other two sorts of cuts and the cutting process, making blunt cuts unique.

Leaving the end connected and uncut allows the end user to cut to the right length. However, it also requires more work to set up.

It is best to place the wire into a screw terminal or any other connection that will puncture the insulation to establish contact with the conductor.

Partial wire cutting and stripping

In between a full strip and a blunt method is the partial strip. It occurs when an electrical wire or cable is cut to length without removing insulation.

It leaves the insulating jacket intact to prevent damage to the inner conductor from the environment.

Partially strip rather than completely strip when performing a partial cut, and the strip is helpful when a little portion of the wire has to be seen, like when splicing or connecting to a terminal block.

Combining Value-Added Services

Apart from the core services of wire cutting and stripping, some companies provide supplementary value-added services such as labeling, bundling, and custom cutting to length.

You can manage wires and reduce tripping hazards if labeled and bundled. Custom cutting also helps installers save time and work more efficiently.

Since terminations can take much time, it makes sense to bundle related services together to save time and money.

The goods will be completely ready for installation upon arrival at the location.

Cable stripping crimping tool

Cable stripping crimping tool

Different Methods for Wire Cutting & Stripping

Both manual instruments, such as wire cutters and strippers, and automated machines are available for cutting and stripping wire.

The benefits of each alternative change depend on the circumstances and the amount of forethought given to its implementation.

Cutting & Stripping By Hand

Due to its portability, speed, and precision, you often use hand strippers to sever the wires. 

In addition, when fixing or repairing wires, electricians cut and strip by hand to reduce the chance of getting hurt wires.

Hand-operated wire and cable cutters have been around for centuries.

The most versatile choice is manual wire strippers, which can crimp the terminals or combine the wires of different electrical cables.

Here is how to cut and strip by hand.

Determine the wire gauge and type.

The first thing you should do is determine how long a piece of wire will need to be and then label it.

First, determine the wire gauge if you want to strip the wire by hand.

It will help you know how far into the outer sheathing to cut before you damage the inner conducting metal.

Match the wire to the tool.

It is a crucial stage since the “cleanness” of the cut depends on inserting the wire into a hole of the right size.

If the selected AWG is too tiny, the conductor might be severed.

However, if it is too large, the outer insulation/jacketing would be much more difficult to peel off.

Open the tool and seat the wire.

Third, cut out some of the insulation from the bare wire end using wire strippers.

Put the wire through the correct opening, then exert pressure up to the breaking point.

This technique can create a tiny hole in the insulation for the junk to escape.


Fourth, twist the bare metal wires together to secure the connection. Twisting is necessary when cutting the insulation is unsuccessful.

You can finish smaller, uncut parts by twisting around the already-penetrating insulation.

Strip the insulation

Remove the cable’s insulation as a last step. It’s as simple as removing a sock by holding both ends and slowly pulling them apart.

Use a smaller gauge if you’re having trouble with this section.

Wire Cutting and Stripping Machine

Superior machinery is used for the automated Cutting and stripping process.

This automated procedure is also used when you need to cut several wires to the same length and strip them in the same manner.

The strippers keep one side of the wire steady while they cut and remove the other.

Automated wire-cutting machines are used a lot in industry and manufacturing because they are versatile.

Using them is easier and more reliable than cutting and stripping wires by hand.

Even a novice may swiftly and easily cut and strip most wires with the help of an automatic wire stripper.

Automated wire-cutting equipment can shorten the time to cut and strip the wire,  increasing productivity.

The three main parts of these devices are the wire feeding mechanism, the cutting mechanism, and the stripping mechanism.

Sheathing for wires may be easily removed and peeled away with only a single press of the handles.

How you’d operate a machine that cuts wires automatically

In the first step, ensure your machine has the correct Cutting and stripping blades for the size and wire you’ll work with. 

The second step is to load the machine with the wire spool and adjust the controls to the desired wire and stripping lengths.

When the wire has been fed into the machine, the machine will automatically strip the insulation off the ends and cut the wire to the desired length. 

Next, collect the shortened and stripped wire, and remove the insulation.

The Stripper tool cuts wires

The Stripper tool cuts wires

Safety Measures When Cutting and Stripping Wires

You must take care while cutting and stripping wires because of the risks involved in dealing with electricity. Here are some safety measures to take when cutting and stripping wires.

  • When stripping thin wires, such as the cables used for television and the internet, you must take more care to avoid breaking them with an adjustable stripping tool.
  • Use a specialized stripping tool to get to the wires inside the plastic-sheathed cable.
  • Whenever you need to work on electrical wires, ensure they are not energized first. To be extra cautious, use strippers with insulated handles. Ensure you closely monitor the process to avoid destroying things or sparking an electrical fire.
  • A licensed electrician should only handle coaxial cabling and wall-and-ground installations.

Wire Cutting & Stripping Services at Cloom

Cloom cut and strip wires precisely and cleanly using machinery made by Schleuniger and other leading equipment manufacturers.

Wire-cutting and stripping services include:

  • Cut to length
  • Multi-step stripping
  • Partial or Full  strip  right and left
  • Multi-layer Cutting and stripping
  • Multi-conductor cables’ Jacket stripping 
  • Multi-layer with shield processing
  • Jacket and inner conductor stripping
  • Jacket stripping of extremely thin insulators
  • Multi-step stripping with inner conductor stripping
Electrical cable wires

Electrical cable wires


Cutting and stripping wires has become an increasingly important electrical service in the past decades.

Every application, from the simplest to the largest industrial processes, differs.

It has the potential for increased efficiency and lower costs through Cutting and stripping.

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