Stripping

Stripping & stripping of copper wires for the electronics industry

+43 (0)1 489 19 03

Stripping

Precise, non-contact and reliable wire preparation for modern production processes

Laser systems from Penteq offer the perfect solution for customer-specific requirements for process-reliable and highly productive systems for the residue-free removal of insulating plastics.

Laser stripping of enamelled copper wires

Enamelled copper wires (also known as insulated copper wires or magnetic wires) are used in a wide range of electrical applications - from transformers and electric motors to high-frequency coils in communications and automotive technology. The removal of the insulation layer - an essential step before contacting, soldering or crimping - places particular demands on precision, reproducibility and material protection.

Laser stripping is establishing itself as a modern, high-precision alternative to mechanical or chemical processes. It is non-contact, wear-free, gentle on materials and ideal for automated production lines.

What is laser stripping?

Laser stripping utilises targeted laser energy to selectively remove the enamel or enamel coating from copper wires - without damaging the underlying copper. The insulation enamel is vaporised or removed using precisely controllable parameters, while the underlying metal structure remains intact.

Typical insulation materials:

polyurethane
polyesterimides
Polyamide imides
Polyetheretherketone (PEEK)
Special coatings for high frequency or high temperature

Advantages over conventional methods

Kriterium	Mechanisch/Chemisch	Laserverfahren
Kontaktfreiheit	❌ Werkzeugkontakt	✔️ Berührungslos
Werkzeugverschleiß	❌ Regelmäßiger Austausch	✔️ Kein Verschleiß
Prozessgenauigkeit	❌ Toleranzen durch mechanische Kräfte	✔️ Mikrometergenaue Steuerung
Materialschonung	❌ Gefahr von Drahtbeschädigung	✔️ Keine mechanische Belastung
Umweltaspekte	❌ Einsatz von Lösungsmitteln	✔️ Trocken, umweltfreundlich
Automatisierung	⭕ Eingeschränkt	✔️ Hoch automatisierbar

Functionality and process parameters

Laser stripping is carried out in a controlled process in which specific parameters are precisely adapted to the wire diameter, insulation material and geometry.

Relevant parameters:

Laser source: fibre laser, diode laser, UV or CO₂ laser - depending on the insulation material
Wavelength: typically 1064 nm (IR) or 355 nm (UV) for finer coatings
Power & pulse duration: short pulse or continuous wave, depending on the application
Removal strategy: spiral, line or dot removal
Positioning: by scanner, CNC gantry or robot arm

Suitable wire types:

Round wire (Ø 0.05 mm - 2 mm)
Rectangular wire / flat wire
Stranded wire and multi-core cables (partly with restrictions)

Application examples

Automotive industry

Stripping of winding wires for electric motors (e.g. hairpin technology)
Preparation for ultrasonic welding or crimping

Electrical engineering & transformer construction

Wire contacting without damaging the winding
Consistent quality for mass production

Medical technology & sensor technology

Ultra-fine wires with very thin insulation
Absolute process purity required (no abrasion, no flux)

Quality assurance and validation

Clean stripping is a prerequisite for good electrical and mechanical connections. The quality of the laser ablation can be tested using the following methods:

Microscopy: evaluation of the surface structure
Contact resistance measurement: quantifying connection quality
Tensile tests / pull-off force measurement
Inline camera control for process monitoring

Optionally, systems can be combined with automatic position detection and removal control to minimise rejects. minimise waste.

Integration in production environments

Modern laser systems have a modular design and can be easily integrated into production lines or cells. Typical interfaces:

PLC / fieldbus systems
Robot connection
Vision systems for position detection

Inline processes can be realised with cycle times in the seconds range - without significant downtimes.

Economic and ecological aspects

Reduction in operating costs due to elimination of tool wear
No chemical waste or solvents
Low maintenance - high system availability
Reproducibility minimises rework and quality fluctuations

Highly precise, reliable & future-proof

Laser stripping of enamelled copper wires is a highly precise, reliable and future-proof process. It enables contactless and non-destructive preparation of wire connections - ideal for automated production processes in demanding industries. The combination of quality, process reliability and environmental friendliness makes the process a clear alternative to conventional stripping methods.