Design World

  • Home
  • Technologies
    • ELECTRONICS • ELECTRICAL
    • Fastening • joining
    • FLUID POWER
    • LINEAR MOTION
    • MOTION CONTROL
    • SENSORS
    • TEST & MEASUREMENT
    • Factory automation
    • Warehouse automation
    • DIGITAL TRANSFORMATION
  • Learn
    • Tech Toolboxes
    • Learning center
    • eBooks • Tech Tips
    • Podcasts
    • Videos
    • Webinars • general engineering
    • Webinars • Automated warehousing
    • Voices
  • LEAP Awards
  • 2025 Leadership
    • 2024 Winners
    • 2023 Winners
    • 2022 Winners
    • 2021 Winners
  • Design Guides
  • Resources
    • Subscribe
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Educational Assets
    • Engineering diversity
    • Trends
  • Supplier Listings
  • Advertise
  • Subscribe

How an Electrical Cable Is Made

By Emily Greenhaw, Quail Electronics | April 26, 2016

The world of electricity can be very complicated. But what about electricity do we, in fact, know? Well, we do know electrical wires are designed to carry current from one element to another. What we DON’T know is how an electrical wire is even made. Of course, as always, I am here to help with any confusion!

A conductor is a material in which electricity can flow through. Electrical conductors are made up of metals such as, copper, aluminum, etc. These metals are used to make wires. Most wires are made out of copper because it conducts electricity with high flexibility and very little resistance.

The first stage in the manufacturing process of a conductor is the wire-drawing. The wire-drawing consists of reducing the diameter of the wire gradually to fit its final diameter to increase ductility and conductivity.

Once the diameter is reduced, the wire is drawn further to decrease the diameter of the wire to the size needed for each kind of conductor.

In the second stage of this process, the wires undergo a heat treatment called annealing. Annealing is a process of heating metal and allowing it to cool slowly in order to remove internal stresses and toughen the metal. The point of this treatment is to increase the conductivity of the wire.

Now we need insulation. Insulators are different synthetic materials that are used to insulate electrical wires. Because the current runs along the outside of the copper wires, they need to be insulated from other wires and conductive surfaces. An insulating cover over the conductor also prevents any current leakages.

Different insulation materials may be used depending on the characteristics of the cable required. Quality of an insulation material depends on two basic characteristics: insulation capacity and its heat resistance.

Cables sometimes contain several different wires wrapped together in an insulator. In some cases, the cable may require additional elements in order to improve protection. For instance, electrical coverings called “screens” insulate the signals that circulate in the cable, shielding the power cables to prevent them from external interference.

And THAT is how an electrical conductor is made!

This blog originally appeared on www.blogquail.com/electrical-cable. 

You Might Also Like


Filed Under: Cables + cable management, Industrial automation

 

LEARNING CENTER

Design World Learning Center
“dw
EXPAND YOUR KNOWLEDGE AND STAY CONNECTED
Get the latest info on technologies, tools and strategies for Design Engineering Professionals.
Motor University

Design World Digital Edition

cover

Browse the most current issue of Design World and back issues in an easy to use high quality format. Clip, share and download with the leading design engineering magazine today.

EDABoard the Forum for Electronics

Top global problem solving EE forum covering Microcontrollers, DSP, Networking, Analog and Digital Design, RF, Power Electronics, PCB Routing and much more

EDABoard: Forum for electronics

Sponsored Content

  • Widening the scope for machine tool designers with FORTiS™ enclosed encoder
  • Sustainability, Innovation and Safety, Central to Our Approach
  • Why off-highway is the sweet spot for AC electrification technology
  • Looking to 2025: Past Success Guides Future Achievements
  • North American Companies Seek Stronger Ties with Italian OEMs
  • Adapt and Evolve
View More >>
Engineering Exchange

The Engineering Exchange is a global educational networking community for engineers.

Connect, share, and learn today »

Design World
  • About us
  • Contact
  • Manage your Design World Subscription
  • Subscribe
  • Design World Digital Network
  • Control Engineering
  • Consulting-Specifying Engineer
  • Plant Engineering
  • Engineering White Papers
  • Leap Awards

Copyright © 2025 WTWH Media LLC. All Rights Reserved. The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of WTWH Media
Privacy Policy | Advertising | About Us

Search Design World

  • Home
  • Technologies
    • ELECTRONICS • ELECTRICAL
    • Fastening • joining
    • FLUID POWER
    • LINEAR MOTION
    • MOTION CONTROL
    • SENSORS
    • TEST & MEASUREMENT
    • Factory automation
    • Warehouse automation
    • DIGITAL TRANSFORMATION
  • Learn
    • Tech Toolboxes
    • Learning center
    • eBooks • Tech Tips
    • Podcasts
    • Videos
    • Webinars • general engineering
    • Webinars • Automated warehousing
    • Voices
  • LEAP Awards
  • 2025 Leadership
    • 2024 Winners
    • 2023 Winners
    • 2022 Winners
    • 2021 Winners
  • Design Guides
  • Resources
    • Subscribe
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Educational Assets
    • Engineering diversity
    • Trends
  • Supplier Listings
  • Advertise
  • Subscribe
We use cookies to personalize content and ads, to provide social media features, and to analyze our traffic. We share information about your use of our site with our social media, advertising, and analytics partners who may combine it with other information you’ve provided to them or that they’ve collected from your use of their services. You consent to our cookies if you continue to use this website.