Wire wrapping - Page 1
Forum section: electronics / general

author: Maxlor
author_rank: Frequent Contributor
timestamp: November 29, 2013, 10:18:50 pm
content: A while ago, I found some old videos on wire wrapping. We still use wire wrapping wire these days, but does anyone actually still do wire wrapping?I've not done it myself, but it seems like an elegant way to make connections. You know, easy to do, easy to undo, not accidentally burning yourself, no fumes... and the result looks very cool, in a steampunk kind of way. Unfortunately, the major distributors don't seem to carry the wrapping tools anymore.So how do the (older, I guess) folks that have done it look at it? Is it something still worth doing, or is there a glaring downside I'm not aware of?

author: IanB
author_rank: Super Contributor
timestamp: November 29, 2013, 10:24:15 pm
content: I think it probably became obsolete with the shift to SMD packages?

author: Six_Shooter
author_rank: Regular Contributor
timestamp: November 29, 2013, 10:27:29 pm
content: Quote from: IanB on November 29, 2013, 10:24:15 pmLOL, you wouldn't be wire wrapping directly to a device anyway.It's something I want to learn the proper techniques of, only because I would like to repair and restore some older equipment as I come across it. If I'm not worried about a proper restoration, I would just solder it.

author: madires
author_rank: Super Contributor
timestamp: November 29, 2013, 10:35:45 pm
content: It's still used for wiring telecommunications stuff by some telcos.

author: Neilm
author_rank: Super Contributor
timestamp: November 29, 2013, 11:14:11 pm
content: I've seen wire wrapping used in some ATE test jigs. Useful if you might need to make a good connection that can easily be re-wired if the circuit changes.

author: KJDS
author_rank: Super Contributor
timestamp: November 29, 2013, 11:31:32 pm
content: i was taught how to do it at university but haven't used it since.

author: Kjelt
author_rank: Super Contributor
timestamp: November 29, 2013, 11:42:35 pm
content: I use the wire and tool to twist the wire a few turns on a through hole component lead while bread boarding, so the wire is mechanically connected prior to soldering it. So it was taught to me by my teacher, always make sure every connection is mechanically strong connected as step 1 , then make a good solder connection. If the solder connection ever fails for any reason, the mechanical connection will still make the electrical connection. Worked for me, my DIY products from the 80's still function

author: Fsck
author_rank: Super Contributor
timestamp: November 29, 2013, 11:45:12 pm
content: Quote from: Kjelt on November 29, 2013, 11:42:35 pmisn't soldering it counter-intuitive to the purpose of wire wrapping?

author: Kjelt
author_rank: Super Contributor
timestamp: November 30, 2013, 12:35:10 am
content: What i do is not wirewrapping as they did in the early days. Then they turned the wires multiple times over the specially formed goldplated pins and that was the only connection. I turn the wire once sometimes twice around the lead of the component that is in a prototyping board. If i would not solder it the component would still be quite loose. I said i just use the tool for the turning.As an answer to the OP a big downturn of the real wirewrapping is that usually all the wire is a single color and because there are hundreds of wires it is difficult to check or find a faulty or missing connection.

author: SeanB
author_rank: Super Contributor
timestamp: November 30, 2013, 06:40:08 am
content: Wire wrap is used where you want a reliable connection that will survive a lot of vibration, like avionics. Mostly used on backplanes as the connectors are made for wire wrap in most cases. But they only are used for low density boards, high density or high frequency you use either a PCB or cable, either flexible or rigid or semi rigid.

author: westfw
author_rank: Super Contributor
timestamp: November 30, 2013, 08:47:48 am
content: Sockets are sorta expensive. And it's pretty slow.

author: TerraHertz
author_rank: Super Contributor
timestamp: November 30, 2013, 09:30:45 am
content: I've done a *lot* of wire wrapped stuff back in the 80s. And still have the tools, somewhere.One reason it sucks, is that a 'proper' wrap connection has two or three turns of insulated wire around the pin, before the bare wire tight turns that make the contact. Those insulated turns are for mechanical robustness - they give the wire run a solid anchor that will withstand tugs and repeated flexing.But the downside is they are also inductive. Just one more reason why wire wrapped circuits have a pathetically low upper frequency limit.

author: SeanB
author_rank: Super Contributor
timestamp: November 30, 2013, 09:36:53 am
content: That is a modified wrap, the original wrap has a the insulation cut right at the first turn. This however tends to fatigue with vibration. A modified wrap however can crack if the solid wire is nicked on the strip point and snaps in service, which then is intermittent or open but still firmly wrapped.