How to Strip Copper Wire Safely and Efficiently

There are several reasons why you would need to strip copper wire. Perhaps you recycle copper wire. Maybe you're an electrician or hobbyist setting up a new circuit. No matter what your reason, poorly stripped wire can be a pain (and maybe even dangerous). 

Something as simple as faulty connections account for 20% of electrical home fires. If you are handling electronic items or scrapping copper wires in bulk, let's get to it and find out how to strip copper wire safely and efficiently.

How to Strip Copper Wire by Hand?

The simplest method for stripping insulation from copper wire is hand-stripping. It might not be the fastest way to do it for massive projects, but you can use it for small-scale jobs or when dealing with delicate wires. Let's explore the tools needed and show you how to strip copper wire by hand.

Tools needed

1. Wire strippers
2. Utility knife
3. Pliers

Step-by-step Process

Step 1: Measure and Mark

Precision is key here. Measure how much of the insulation you will have to remove and make a visible mark on your wire. A fine point marker will get the job done but if you have some time and want a very clean-looking cut grab yourself a masking tape.

Step 2: Score the Insulation

This step requires a delicate touch. Slice around the wire at your marked point with a utility knife or even wire strippers. 

The aim is to strip away the insulation, without breaking through all of the way down and hitting the copper core. For stranded wire, be extra cautious; nicking even a few strands can compromise the wire's integrity.

Step 3: Bend and Break

Once scored, gently bend the wire at the marked point. This technique works particularly well for solid core wires, causing the insulation to separate cleanly. 

For stranded wires, use a lighter touch to avoid separating the individual strands. If the insulation proves stubborn, don't force it – simply score it again, slightly deeper this time.

Step 4: Remove Insulation

Here's where your pliers come into play. Grip the scored section firmly and pull it away from the wire with a steady, even motion. 

The insulation should slide off, revealing the shiny copper core beneath. If you encounter resistance, try twisting the insulation slightly as you pull – this can help break any remaining connections.

Step 5: Clean the Exposed Copper

The final touch – and one often overlooked – is to ensure the exposed copper is pristine. If necessary, use fine-grit sandpaper to remove any lingering insulation residue. A light touch is crucial here; you want to clean the copper, not remove it. 

Pros of Hand Stripping

• Offers precise control, making it ideal for delicate or small-gauge wires
• Requires no special equipment beyond basic hand tools
• Perfect for occasional or small-scale projects
• Allows for careful inspection of the wire during the stripping process

Cons of Hand Stripping

• Time-consuming for large volumes of wire
• Carries a risk of damaging the copper core if not done carefully
• Can lead to repetitive strain injuries during extended use
• Maintaining consistency can be challenging, especially for beginners

This brings us to using handheld tools for stripping copper wire. They eliminate all the cons of stripping copper wires by hand.

Steps for Stripping Copper Wire with Manual Tools

Let’s say you own a nifty manual wire stripper like the one we offer with 0.06"-1" Copper Wires Recycling, follow the steps below:

Step 1: Select the Right Size

Most wire strippers feature multiple notches, each designed for a specific wire gauge. Choose the appropriate size for your wire. 

When in doubt, start with a larger opening and work your way down. This approach prevents accidentally cutting into the copper core, which can weaken the wire or create a potential failure point.

Step 2: Position the Wire

Insert your wire into the chosen notch, aligning it with the desired stripping point. Many quality strippers have a built-in stop or guide to ensure consistent strip lengths. For precision work, you might even mark your desired strip length on the tool itself with a piece of tape.

Step 3: Apply Pressure

Close the stripper handles firmly, allowing the blades to penetrate the insulation. The key here is to apply enough pressure to cut through the insulation without damaging the copper within. 

If you're using adjustable strippers, you may need to fine-tune the tension for optimal results. It's worth taking the time to get this right – a perfectly adjusted stripper can make your work significantly faster and more consistent.

Step 4: Score Completely

For non-automatic strippers, rotate the tool around the wire to ensure you've scored the entire circumference. This step is crucial for achieving a clean strip, especially on tougher insulations. Think of it like cutting around a tree trunk before felling it – a complete score ensures a clean break.

Step 5: Remove the Insulation

With a smooth, steady motion, pull the stripper away from the wire end. The insulation should separate cleanly, revealing the copper beneath. 

If you encounter resistance, resist the urge to force it. Instead, check if you need to score the insulation more deeply or if there's any damage to the wire. A clean strip should come away easily, leaving the copper core untouched.

For those who find themselves stripping wire regularly but aren't quite ready for a fully automated system, the CREWORKS Manual Wire Stripping Machine offers an excellent middle ground.

CREWORKS Manual Wire Stripping Machine

Here’s our Manual Wire Stripping Machine for 0.06"-1" Copper Wires Recycling. This bench-mounted tool significantly increases stripping speed and consistency while still providing hands-on control.

Key features

• Adjustable feed hole (0.06"-1"): This wide range covers most common wire gauges, from delicate electronics wiring to thicker power cables. 
• Durable construction: Crafted from aircraft-grade aluminum alloy, this machine is built to last.
• Hand crank mechanism: The manual crank allows for controlled operation speed, giving you the ability to adjust based on wire type and your comfort level.
• Versatility: Suitable for a wide range of wire types, including automotive and audio cables, this machine can handle both solid core and stranded wires with equal efficiency.

Imagine you're working on restoring a classic car, with a mix of original wiring and modern replacements. The manual stripper would allow you to switch easily between different wire types, maintaining the original wiring where possible while efficiently preparing new connections.

How to Strip Copper Wire Fast with Automated Machines

When dealing with large quantities of wire or regularly stripping as part of your work, you will appreciate the endurance and efficiency of automated wire stripping machines. 

These devices offer unparalleled speed and consistency, making them essential for industrial applications, large-scale recycling operations, or high-volume electrical work.

Benefits of automated stripping

1. Automated machines can strip hundreds of feet of wire per hour, far outpacing manual methods. This speed helps you to meet your production deadlines or process large quantities of scrap wire.
2. Automated machines make exact cuts, stripping every wire the same way. In manufacturing, or in recycling to get the highest value from your feed stream this level of consistency can be a real benefit.
3. Minimize repetitive motions that can lead to fatigue or injury. By automating the stripping process, workers are spared the repetitive hand movements that can lead to conditions like carpal tunnel syndrome.
4. Many machines can handle a wide range of wire types and sizes. Advanced automated strippers can quickly adjust to different wire gauges and insulation types, often with minimal setup time. This flexibility allows for efficient processing of mixed wire batches without constant retooling.

CREWORKS Automatic Wire Stripping Machine

An example of how automation can change the game is demonstrated by this Automatic Wire Stripping Machine from CREWORKS. Its mix of speed, precision, and flexibility makes it capable of covering a variety of applications.

Key features

• Handles wire diameters from 0.06" to 1": This wide range covers the most common wire sizes, from fine gauge wires used in electronics to thicker cables used in power distribution. 
• Adjustable stripping length and depth: Users can fine-tune the machine to achieve perfect strips for any wire type. 
• High-speed operation for increased productivity: With the ability to process wire much faster than manual methods, this machine can significantly boost output. In recycling operations, this speed can translate directly into increased profitability.

Wrapping Up

The choice, as always, is yours. All of us have different needs. If you searched “how to strip copper wire” just to learn a simple way to do it safely, then the section on stripping by hand will suffice. But if you’re an electrical technician, you don’t want to risk inconsistencies. 

DIYers are not left out—you want your projects wired up without issues. For the last two groups, we recommend the CREWORKS range of manual wire strippers. Do you strip copper wire on a large scale? Then one of our automatic strippers will take your stripping business to the next level.