Author: Site Editor Publish Time: 2025-08-18 Origin: Site
In modern OEM manufacturing and industrial installations, efficiency and safety are top priorities. Stripped power cords are pre-manufactured cables with conductor ends already stripped of insulation. They play a critical role in achieving both goals.
These cords are designed for quick connection to terminals, circuit boards, or custom connectors. Instead of manually stripping wires on-site, engineers can work with cables that arrive ready for integration. This reduces assembly time, minimizes the risk of wiring errors, and ensures a consistent quality standard across production batches.
Stripped power cords are especially popular in:
OEM assembly lines where every second counts
Industrial control panels that require precise wiring
Custom machinery that integrates multiple electrical systems
By outsourcing the stripping process to a certified cable manufacturer, companies can save labor costs, reduce downtime, and maintain compliance with safety standards.
If you want to appreciate their value, it's important to understand how stripped power cords are built.
Conductors – Their conductors are usually copper (bare or tinned) for optimal conductivity.
Insulation – Thier insulations are made of PVC, TPE, FEP, or PTFE for mechanical protection and dielectric strength.
Outer Jacket – The outer jacket of the stripped power cord provides environmental protection and mechanical durability.
Stripped Ends – They mean pre-removed insulation to expose a precise length of conductor.
Fully Stripped: Insulation removed entirely from the conductor ends
Ideal for direct terminal connections in control panels, circuit breakers, and junction boxes where immediate wiring is required.
Used in factory-prepared OEM assemblies where speed of connection is critical and no further stripping tools are needed on the production line.
Common in temporary wiring setups for testing or prototyping, allowing quick attachment to screw-type terminals or wire nuts.
Suitable for custom cable assemblies shipped to installers who will terminate the wires into equipment immediately upon receipt.
Partially Stripped / Half-Strip: Insulation loosened but not fully removed, allowing final stripping during assembly
Preferred in shipping-sensitive applications where conductors must remain protected during transport but allow quick final prep at installation.
Often chosen for field assembly kits where installers want to adjust the stripped length based on specific terminal block dimensions.
Reduces oxidation risk of exposed copper during storage before final assembly.
Popular in exported machinery wiring harnesses, where the final stripping is done to match different international terminal standards.
Twisted Ends: Stripped conductors twisted to prevent fraying during installation
Standard practice for multi-strand copper conductors connecting to screw or clamp terminals, ensuring a secure, clean insertion.
Used in control cabinets, switchboards, and lighting fixtures to avoid stray strands that can cause shorts.
Often found in audio, telecommunications, and low-voltage control wiring, where neatness and consistent contact are essential.
Helpful in assembly-line wiring where cables are inserted into push-fit connectors or ferrules.
Tinned Ends: Conductors coated with solder to improve connection quality and corrosion resistance
Essential for marine, outdoor, and humid environment applications, as tinning protects against oxidation and corrosion.
Common in electronics assembly for soldering directly to printed circuit boards (PCBs) or connector pins.
Used in renewable energy systems (solar panels, wind turbines) where cables face exposure to moisture and temperature changes.
Helps in precision equipment wiring by ensuring consistent electrical conductivity and easier solder wetting during final assembly.
Favored for vibration-prone environments (transportation, heavy machinery) because solder bonds reinforce the conductor ends.
Voltage ratings commonly range from 125V to 300V for standard power cords, and up to 600V for industrial-grade designs
AWG sizes typically range from 18 AWG (light-duty applications) to 12 AWG (heavy-duty power supply lines)
Understanding these variables is crucial for matching the right stripped power cord to the application's electrical load and environmental conditions.
Safety is one of the most critical aspects when working with stripped power cords, especially in industrial settings where high currents and voltages are involved.
If stripped ends are left too long or improperly trimmed, exposed conductors may come into contact with nearby terminals or metal surfaces, causing a short circuit.
Industry guidelines, such as those from UL (Underwriters Laboratories), specify the maximum allowable exposed conductor length for different connection methods. This ensures a secure connection without excessive bare wire that could lead to accidental contact.
Manufacturers and OEMs should ensure that stripped cords comply with:
UL (North America)
VDE (Europe)
SAA (Canada) These standards govern conductor length, insulation integrity, and overall product safety.
Even with perfectly stripped ends, mechanical strain on the cord can loosen connections. Proper strain relief, such as molded boots, grommets, or clamp-style connectors, protects the conductor terminations from mechanical stress and extends the product's lifespan.
One of the biggest advantages of stripped power cords is how easily they can be tailored to fit specific industrial needs.
Smaller gauge (e.g., 18 AWG) – for control signals and low-power devices
Larger gauge (e.g., 12 AWG) – for motors, heaters, and heavy-duty machinery
PVC – Cost-effective and flexible for indoor use
TPE – Superior flexibility and oil resistance
FEP/PTFE – High-temperature resistance, chemical resistance, and low friction for harsh environments
Solid conductors – Better for fixed installations where the wire doesn't move
Stranded conductors – More flexible, ideal for moving machinery parts
Bare copper ends for quick screw-terminal connections
Tinned ends for soldering or corrosion-prone environments
Ferrule crimps for secure screw clamp terminations
In 2-prong, 3-prong, or multi-prong cords, color-coded insulation helps prevent wiring errors and improves maintenance safety. Common color codes include:
Black / Brown – Live/Hot
White / Blue – Neutral
Green / Green-Yellow – Ground/Earth
For Original Equipment Manufacturers, stripped power cords offer multiple operational and cost advantages.
No need for workers to strip insulation on-site — the cord arrives ready for installation, speeding up production lines.
Factory-prepared stripped ends ensure consistency in conductor length, twist tightness, and tinning quality.
Skilled labor time is expensive. Using pre-stripped cords reduces manual steps, lowering the chance of human error.
Pre-finished cords with standard lengths and specifications make it easier to manage stock and maintain product uniformity.
By working with a trusted supplier like A-Line Cable, OEMs can outsource both stripping and quality assurance, ensuring every cord meets required tolerances and certifications.
Choosing a capable supplier can be the difference between trouble-free production and costly rework.
Look for suppliers with certifications such as UL, SAA, and VDE. These demonstrate that their processes meet recognized safety and quality standards.
The supplier should be able to handle a variety of cord types, jacket materials, and end treatments. They should also provide documentation for compliance.
OEMs often need both large production runs and smaller custom orders. Choose a supplier that can handle both without long delays.
A-Line Cable specializes in producing custom stripped power cords for industrial, OEM, and export markets. With a full range of jacket materials, AWG sizes, and stripping styles — plus compliance with UL, SAA, and VDE — they deliver reliable solutions that balance safety and customization.
Stripped power cords may seem like a small component, but in industrial and OEM applications, they have a big impact. Properly designed cords improve safety by minimizing short-circuit risks and ensuring compliance with international standards. They also help OEMs streamline production, cut labor costs, and maintain consistent quality.
For reliable, safe, and customizable stripped power cords, partner with a certified manufacturer like A-Line Cable. With expertise in materials, conductor sizing, and end treatments, they can deliver cords that fit your exact application — on time and to spec.
Ready to improve your production line efficiency and product safety?
Contact A-Line Cable today to discuss your stripped power cord needs and receive a tailored solution.
