In the intricate world of electronics, particularly in critical industries like medical devices even the slightest electrical noise can have significant consequences. A key factor in minimizing this noise is the quality of wire stripping. For years, mechanical methods like rotary cones, tweezers, and scraping have been the traditional tools for this task. However, these methods, while effective in certain scenarios, often fall short in delivering the precision and consistency required for optimal performance often leading to high scrap levels.
What is Wire Stripping?
Before the wires or cables can be connected to the PCB or connector, it is necessary to individually expose the conductor and align them with the mating connection on the PCB / connector. This process step is called the “wire or cable stripping”.
The Evolving Landscape of Wire Stripping
The wire stripping industry has witnessed a steady evolution, driven by the increasing demand for higher performance and reliability in electronic devices. As these industries adhere to stringent standards and guidelines, the need for precise and consistent wire stripping has become paramount. For example, in the medical device industry, even a minor electrical interference can compromise the safety and efficacy of life-saving equipment. Similarly, in the automotive and aerospace sectors, reliable electrical connections are crucial for ensuring the safety and performance of vehicles and aircraft.
The Challenge of Achieving a Clean Strip
While mechanical methods have been the industry standard for decades, they face inherent limitations. Cables are often not perfectly cylindrical, and their surface can vary in texture and hardness. These irregularities can lead to inconsistent stripping results, leaving behind microscopic burrs and residue that can degrade signal integrity and increase the risk of electrical noise. Additionally, manual methods can be time-consuming and prone to human error, further compromising the quality of the stripping process.
In addition, for cable with an outer diameter much below 0.1” (0.25mm) mechanical stripping is not an option. The mechanical units can also only strip one cable at a time, using them causes challenges when having to connectorize large numbers of wires and cables to a consistent level of quality.
The New Preferred Method
Laser wire stripping has since become the preferred alternative to traditional methods. By utilizing a precisely focused laser beam, this technology can remove insulation with exceptional accuracy and consistency.
The light is focused to a small spot of typically 0.1” (0.25mm) in diameter and is passed over the cable from at least 2 sides to form a 360-degree strip. The light heats the polymer causing it to melt or vaporize. A fume extraction filter, as used on a solder station, removes the fume from the process area and neutralises it. This stripping is a thermal process, but by controlling the amount of time the laser is hitting the cable, it is possible to cut and remove the polymer layers without overheating the inner layers of the cable.
The laser’s ability to vaporize or ablate the insulation material eliminates the risk of mechanical damage to the underlying conductor, ensuring a clean and burr-free strip.
Key advantages of laser wire stripping include:
- Precision and Consistency: Laser technology enables highly precise control over the stripping process, resulting in consistent results across a wide range of wire sizes and materials.
- Minimal Heat Affected Zone (HAZ): Laser stripping minimizes the heat affected zone, reducing the risk of damage to the conductor and surrounding components.
- Reduced Electrical Noise: By ensuring a clean and burr-free strip, laser technology helps to minimize electrical noise and improve signal integrity.
- Increased Productivity: Automated laser systems can significantly increase productivity compared to manual methods, reducing labor costs and improving overall efficiency.
- Environmental Friendliness: Laser stripping is a clean and environmentally friendly process that generates minimal waste.
As the demand for high-performance electronic devices continues to grow, laser wire stripping is emerging as the preferred method for achieving optimal results. By embracing this innovative technology, manufacturers can enhance the reliability and performance of their products while meeting the stringent requirements of modern industries.
