Stranding and bunching involve twisting together multiple wire strands to create a single, larger conductor. Stranding is typically used to increase flexibility and fatigue resistance, while bunching is often employed for applications requiring compact wire with high conductivity. These processes are essential in producing cables and wires for various applications across industries such as electronics, automotive, aerospace, and more.

We work with a wide range of materials to meet the diverse needs of our clients. This includes, but is not limited to, nickel alloys, copper, copper alloys, stainless steel, aluminium, and high-performance materials like nickel-chromium, cupro-nickel, and iron-chrome-aluminium. Our selection of materials ensures we can tailor our services to the specific requirements of each application, considering factors such as conductivity, temperature resistance, and corrosion resistance.

Single strand wire consists of a single, solid wire, while stranded or bunched wire is made up of multiple smaller strands twisted together.

The key difference between single strand and stranded or bunched wire is the flexibility and durability of the wire. Stranded or bunched wire is more flexible and durable due to the number of smaller strands that make up the wire. The smaller strands can move independently, allowing the wire to bend and flex more easily. This feature makes stranded wire less prone to breaking when subjected to repeated bending or vibrations, making it ideal for applications where wire flexibility is crucial.

In contrast, single strand wire is generally stiffer and less flexible, making it more prone to breaking and harder to handle in applications that require frequent movement or bending.

Stranded or bunched wire also offers a higher current-carrying capacity compared to single strand wire, as the multiple strands of stranded wire increase the overall surface area of the wire and enable better dissipation of heat generated by the current.

However, single strand wire is simpler to terminate and connect compared to stranded or bunched wire, as the solid conductor provides a more stable contact surface for inserting into connectors and terminals.

When choosing between single strand wire and stranded or bunched wire, it’s important to consider the specific requirements of your application, such as flexibility, durability, current-carrying capacity, and ease of termination.

At Knight Precision Wire Ltd, we offer a comprehensive range of both single strand and stranded or bunched wire options to cater to different electrical applications’ needs. For more information on which wire option is best suited for your application, please contact us.

There are several types of stranded wire, each designed to meet specific application requirements. Understanding these types will help you choose the right wire for your needs. Here are the most common types of stranded wire and their uses:

Standard Stranded Wire: This is the most common type of stranded wire, consisting of multiple strands of wire twisted together in a geometrical configuration. It offers flexibility, durability, and good electrical conductivity, making it suitable for a wide range of general-purpose applications where flexibility is required.

Tinned Stranded Wire: Tinned stranded wire is coated with a thin layer of tin. This provides excellent corrosion resistance, making it ideal for use in marine, automotive, and harsh environment applications where exposure to moisture or chemicals is a concern. The tin coating also helps with soldering connections, improving the wire’s reliability.

Ultra-Flexible Stranded Wire: Ultra-flexible stranded wire is designed for applications that require exceptional flexibility, such as robotics, automation, and high-flex applications. It typically has a higher strand count and uses thinner gauge strands, making it more flexible than standard stranded wire. Ultra-flexible wire minimises stress and fatigue, allowing for repeated bending and flexing without compromising performance.

High-Temperature Stranded Wire / Resistance Stranded Wire: This type of stranded wire is designed to withstand elevated temperatures without degradation. It is typically made using resistance nickel alloys that can operate under higher temperature ranges. High-temperature stranded wire is used in applications like aerospace, automotive, and industrial settings where exposure to high heat is expected.

Magnet Wire: Also known as winding wire, magnet wire is a type of stranded wire specifically designed for use in electromagnets, motors, and transformers. It has a thin insulation coating that allows for efficient electrical conductivity while occupying less space. Magnet wire is typically made from materials such as copper or aluminum.

When choosing the right type of stranded wire for your application, consider factors such as flexibility, durability, electrical conductivity, corrosion resistance, temperature rating, and current-carrying capacity. If you are unsure which type of stranded wire is suitable for your specific application, our team at [Your Company Name] is here to assist you and provide expert guidance.

Please note that the above information serves as a general guide. For detailed specifications and recommendations, we encourage you to get in touch with our sales team.

Absolutely. We specialise in creating custom solutions tailored to our customers’ unique specifications. Whether you need specific resistance levels, unique sizes, or particular strand constructions, our team is equipped to deliver. We offer standard constructions including 7, 19, 37 strands, and can offer 49 strands by request.  We can accommodate bespoke requests to ensure your project’s exact needs are met. Get in touch with our experienced sales team to discuss your requirements. 

Our stranded and bunched wires are used in a wide variety of applications, including but not limited to resistance heating elements, electronic resistors, automotive cables, aerospace wiring, and medical devices. These wires are also used in applications requiring high flexibility and durability, such as in robotics, moving machinery parts, and high-vibration environments.

Stranded wire can be further categorised based on their lay configuration — that is, how the individual strands are arranged within the wire. These configurations offer unique characteristics and perform differently in various applications. Here are the most common configurations of stranded wire and their uses:

Regular Lay Stranded Wire: In regular lay stranded wire, the individual strands are twisted together in one direction or lay. This configuration provides durability, resistance to bending fatigue, and good flexibility. It is commonly used in applications where flexibility and mechanical strength are important, such as power cables, extension cords, and appliances.

Reverse Lay Stranded Wire: Reverse lay stranded wire is similar to regular lay, but the individual strands are twisted in the opposite direction. This configuration helps counteract the natural tendency of the wire to twist when under torsional stress. Reverse lay stranded wire is commonly used in applications that involve torque or twisting, such as elevator cables and winch ropes.

Unilay Stranded Wire: Unilay stranded wire consists of layers of strands, with each layer having alternate strand directions. This configuration offers great flexibility, making it suitable for applications requiring repeated bending and flexing. Unilay stranded wire is commonly used in robotics, automated equipment, and other high-flex applications.

Bunched Stranded Wire: Bunched stranded wire is made up of individual strands that are lightly twisted without a consistent lay length and direction. This configuration offers superior flexibility, making it ideal for applications where extreme flexibility and maneuverability are required. Bunched stranded wire is commonly used in medical devices, robotics, and electronics.

It’s important to consider the specific requirements of your application when choosing the configuration of stranded wire. Factors such as flexibility, durability, resistance to bending fatigue, and torsional stress should be taken into account. If you have any doubts or need further assistance in selecting the right stranded wire configuration for your application, our knowledgeable team is here to help. You can contact us using our contact form, by telephoning +44 (0)1707 645261 or emailing us at wire.sales@knight-group.co.uk

In addition to different configurations, stranded wire is also specified by the strand count. The most common strand counts include:

7/19 Strand Configuration: This means there are 7 strands, and each of those strands consists of 19 smaller strands. The 7/19 configuration balances flexibility and strength, making it suitable for a wide range of applications, including aircraft control cables, suspension bridge cables, and lifting cables.

3/37 Strand Configuration: This means there are 3 strands, and each of those strands consists of 37 smaller strands. The 3/37 configuration offers excellent flexibility and resistance to bending fatigue, making it well-suited for applications such as overhead cranes, marine rigging, and stage rigging.

49 Strand Configuration: This means there are 49 smaller strands twisted together in a single wire. The 49 strand configuration provides exceptional flexibility, along with high strength and resistance to bending fatigue. It is commonly used in applications that require extreme flexibility and durability, such as audio cables, and high-performance robotics.

It’s important to consider the specific requirements of your application when choosing the configuration of stranded wire. Factors such as flexibility, durability, resistance to bending fatigue, and torsional stress should be taken into account. If you have any doubts or need further assistance in selecting the right stranded wire configuration for your application, our knowledgeable team is here to help. You can contact us using our contact form, by telephoning +44 (0)1707 645261 or emailing us at wire.sales@knight-group.co.uk

Quality assurance is a cornerstone of our operations. We employ advanced manufacturing processes and rigorous quality control measures at every stage of production. Our facility is equipped with dedicated stranding and bunching machinery and our experienced operators ensure precision and consistency.  

Knight Precision Wire are specialist wire and cable manufacturers and can provide free quotations for wire bunching and wire stranding services, based on your individual requirements. You can use our contact form, 01707 645261 or wire.sales@knight-group.co.uk.