Why Do Wire Gauge Sizes Seem To Work Backwards?

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Something that has been a constant source of confusion within many circles, is the question of why do wire gauge sizes seem to be the opposite of what we think they should be? As a wire increases in physical width the gauge of that wire will decrease in numerical value. This seems backwards but, there must be an explanation to this that makes some form of sense.

Determining Wire Gauge Sizes 

Given an example of the wire gauge chart in Figure 1.1 we can see there is an extreme difference in physical size between a 0 gauge wire and that of a 30 gauge wire. The physical size of the 30 gauge is substantially smaller than that of the 0 gauge wire. Why is this?

The physical size of a wire is defined by the number of operations that it takes to get it to that physical size. This process means that a 30 gauge wire is much smaller in size than a 0 gauge wire. This process is called “Wire Drawing” and it looks like Figure 1.2. “Wire Drawing” is what gives us all of the different gauges that are seen in Figure 1.1.

A way to think about the wire drawing process is to think of the process of taffy pulling. Just like that sugary deliciousness, the wire starts off as one larger wire mass. Also, like taffy pulling wire drawing stretches and decreases the physical size of the wire making it longer and thinner. The process of wire drawing and decreasing the gauge of a wire also reduces the current that is traveling through the wire. By reducing the current in smaller gauged wires there is a decrease in the amperage that can be handled.


wire gauge

Figure 1.1 (Standard Wire Gauge Chart)


Figure 1.2 (Wire Drawing to Decrease Wire Gauge) (Kingway)

Now that you know how wire gauges are measured you are ready to start your own wire harness journey!

If you are interested in designing your own wire harnesses check out our new Wire Harness Estimator to get a quote!

If you need more information before you get started check out our blog on The Wire Harness Estimator Components Defined

You can also learn more about our pre-designed wire harnesses by checking out our Wire Harness Page!

Wire Harness Estimate

Do You Need a Wire Harness Estimate, Pronto?


Need a price on a Wire Harness Assembly, like RIGHT NOW?! Traditionally, receiving a Wire Harness Estimate could take hours or even days. Well, thanks to some hard work and innovation that problem is now solved. You can now receive a Wire Harness Estimate within minutes (or even seconds depending on how fast you type). Stop by and check out the brand new Falconer Electronics Wire Harness Estimator.

Wire Harness Estimate in 6 Simple Steps 

The Wire Harness Estimator offers you a simple 6 step process. With each step, you can easily enter product information. Once complete, you hit submit. Within seconds your Wire Harness Estimate will be waiting for you in your email box.

Wire Harness Estimate

  1. Select your wire
  2. Enter the number of wires
  3. Select your terminals
  4. Choose add-ons – such as sleeving, heat shrink, labels, or wire ties
  5. Don’t see an item you need – this step you can type in a request
  6. Submit

At any time you are also free to submit a drawing.

Creating a prototype?

Testing a new product?

Need a Wire Harness Estimate quick? No problem. You can breeze through the Wire Harness Estimator completely free of charge and no obligations.

Questions on Wire Harness Components? Click here.

Custom Wire Harness Assembly 

What type of industries do we serve? Our wire harnesses can be found in the healthcare industry, auto and truck lighting, heating systems, locomotive products and much more.  

Commercial Power Strips

Commercial Power Strips manufactured by Falconer Electronics can be found working relentlessly at numerous major brick and mortar retail stores at product displays. We produce our own wire harnesses for all of our power strips.

Portable Work Lights 

We even produce wire harnesses for our own proprietary product line of portable work lights. This line includes magnetic trouble lights and magnetic spotlights.

MLC-50-C3 Trouble Light


Thank you for reading this post on Wire Harness Estimate. For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.

Wire Harness Estimator Components Defined


Falconer Electronics, Inc recently announced a new tool, the Wire Harness Estimator, to assist with determining the cost of a Wire Harness Assembly (click here to view).

The Wire Harness Estimator allows you to quickly and easily enter the components that make up your wire harness and within seconds you will receive an email with the estimate. 

Below you will find helpful definitions as a guide to use the Wire Harness Estimator. 

Wire Types And What They Are Used For

Stranded: When a wire needs to be flexible within a product.

Flexible Ground Braid: Grounding connection between two terminals while still having the ability to move or vibrate.

Ribbon Cable – Gray: Usually used to make connections within electrical devices such as computers, DVD players, or hard drives.

THHN – Solid: For a fixed application like traveling through straight formed conduit.

THHN – Stranded: For an application where a flexible wire is needed, as when placing wire around corners or in power boxes.

Wire Gauges And How They Are Defined

Wire Gauges We Offer:

22, 20, 18, 16, 14, 12, 10, 8, 6

Figure 1.1

Physical Size of Wire:

The physical size of a wire is defined by the number of operations that it takes to get it to that physical size. This process means that a 22 gauge wire is much smaller in size than a 6 gauge wire. This process is called “Wire Drawing” and it looks like Figure 1.2. “Wire Drawing” is what gives us all of the different gauges that are seen in Figure 1.1. 

The smaller the wire gauge the less current that is traveling through the wire itself. Also meaning the smaller gauged wires have less amperage they can handle. 

Figure 1.2 (Kingway)

Wire Colors And What They Are Used For

Black: Hot/ Positive

White: Common/ Negative

Green: Ground

Red: Secondary Line: Hot/Positive

Blue, Yellow, Brown: Available for customer’s personal choice to connect one point to another.

Terminal Types And Why They Are Needed

Ring Terminal: To connect two points through a wire and is attached with a screw. Figure 2.1

Fork Terminal: Much like that Ring Terminal it connects two points through a wire and is attached with a screw, however it is also useful if you need to remove the terminal from a device because of its open ended design. Figure 2.2

Quick Connect / Disconnect Terminal: Terminals that attach to another terminal by sliding into place. There are female and male connecting terminals. Figure 2.3 and Figure 2.4 

Ferrule Terminal: Fastening, joining, sealing, or reinforcing wires to each other. Can be used in many different applications due to the many different types there are. Figure 2.5


Figure 2.1              Figure 2.2         Figure 2.3        Figure 2.4     Figure 2.5

Terminal Insulation Type And Why They Are Needed


  • Partially Insulated- Usually on ring or fork terminals. Used mostly to prevent crossing/ shorting of the wires by preventing contact with other wires.
  • Fully Insulated- Mostly on Quick Connect/ Disconnect terminals. Fully insulated terminals are mostly used to prevent contact between terminals. Therefore the wires would not be in contact with each other in small spaces. 

Uninsulated- Terminals that need to be crimped in place or soldered in place. Usually, are finished with heat shrink tubing.

Terminal Stud Sizes And Why It’s Important To Know What Size You Need 

Terminal Stud Sizes We Offer:

2,4,6,8,10, 1/4″

                                                       Figure 3.1 

Why is the terminal stud size important:

If your assembly requires that wires are attached by screws or other hardware you need to be sure that you have a proper size to fit the hardware you are using.

Therefore if you are using a 1/4″ screw in your assembly but you have gotten a #2 terminal stud you won’t be able to attach your wire to your assembly. As you can see in Figure 3.1 the sizes are very different.   

The other important thing to remember when looking at terminal stud size is they have to be able to fit around your screw or hardware. This means that a 1/4″ terminal stud will actually be slightly larger than a 1/4″.  

Wire Harness Add-Ons And What They Are Used For

Spiral Wrap: Bundles wires together while still providing flexibility

Wire Ties: Bundling wires into separate groups, separating wires from other wires in harness, or holding a wire into a specific direction

Shrink Tubing: Protecting and insulating wire from outside elements


For more information on our wire harnesses check out our Wire Harness page.

To learn more about these exciting products please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest .







New Wire Harness Manufacturer

How to Find a New Wire Harness Manufacturer – Part 3


Trying to Find a New Wire Harness Manufacturer? You have landed on the right place. As a Custom Wire Harness Manufacturer since 1985, our team at Falconer Electronics has worked with hundreds of customers ranging from many different industries. 

This blog post continues our series on maximizing the due diligence process when searching for a new custom manufacturer to outsource production. In particular, partnering with a New Wire Harness Manufacturer. Each week we are providing a helpful step by step process to provide guidance with your search. 

Previous posts include: 

Outsource Your Wire Harness Assembly Process – Part 1

Selecting a Wire Harness Manufacturer – Part 2

This week we discuss the process of discovering a New Wire Harness Manufacturer. 

How to Find a New Wire Harness Manufacturer? 

Partnering with to a New Wire Harness Manufacturer would be extremely beneficial for your company. Once you have decided to outsource your Wire Harness Assembly process, now the search begins. 

Unless you already have a candidate in mind, most likely you will kick start the process by relying on connections within your network. A great place to start includes the list below: 

  1. Vendors
  2. Suppliers
  3. Customers
  4. Chamber of Commerce or other local connections and business organizations 
  5. Trade Associations

If you lack successful connections going this route, no fear. Call on your dear friend Google. Conducting a few Google searches will show you local and national Wire Harness Manufacturing companies. 

Is geography a critical factor? For example, if you were looking for a supplier of wooden pallets, you need somebody extremely close otherwise shipping costs would be brutal and cost prohibitive. 

With a Wire Harness Assembly, shipping costs are not prohibitive and detrimental. Partnering with the right company in another part of the country can still be an effective relationship. 

Once you have discovered a worthy prospect, begin conducting company research to see if this is a good fit for you. 

Check Out the Company Website:

  1. First, explore the company website. Does the website represent the company as a partner that you can trust?
  2. Does the company reveal itself having the staff, tools, resources, and ability to tackle your project?
  3. Do they serve your industry?
  4. Do they have the experience and expertise to take on your project? 
  5. Proximity? Do they need to be within a certain distance of your facility? 

Check out their Social Media:

  1. Is the company active on social media and communicating their culture?
  2. Does it fit with yours?
  3. Does the company provide helpful tips?
  4. Communicate the company mission? Does the mission fit with yours? 
  5. Can you easily submit a drawing of your wire harness assembly? 
  6. When you contact them, do you receive a quick response? 

Below are a few questions to consider asking: 

  1. Types of customers – What industry does the company target? Do they understand your needs? Can they speak your language? Do you feel a chemistry and kindred spirit with this company? Do they have the flexibility to speed up when during your busier times? Can they adjust to varying seasonal demands? 
  2. Vendor relationships – Do they have outstanding vendor relationships? Do they have purchasing power? Are they willing to negotiate and fight for the lowest cost on product for you? Do they have strong cash flow and pay their bills on time so there are no delays in purchasing your product? 

New Wire Harness Manufacturer

Next week with our series on selecting a New Wire Harness Manufacturer to partner with, we will dig further into questions that you can ask during the interview process. 

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest.

Wire Harness Estimate

How to Use the FEI Wire Harness Estimator


Introducing the FEI Wire Harness Estimator

Falconer Electronics, Inc (FEI) proudly announces launching the brand new FEI Wire Harness Estimator. Our team is extremely excited to share this new tool with customers: https://falconerelectronics.com/custom-wire-harness-estimator/

Especially those who are eager to capture an estimate or ballpark price on their Wire Harness Assembly quickly and easily. Below offers a step by step process when using the FEI Wire Harness Estimator. 

Steps to Complete the FEI Wire Harness Estimator


Step 1 – Select Wire Type 

FEI Wire Harness Estimator


You may select multiple wires – Click “Add to Estimate” after each selection 

Options include:

Wire Stranded

  • Available Colors – Black, White, Green, Red, Blue, Yellow, Brown
  • Available Gauges – 6, 8, 10, 12, 14, 16, 18, 20, 22  

Flexible Ground Braid 

  • Uninsulated  
  • 1/4″ and 1/2″ 

Ribbon Cable – Gray 

  • Available Color – Gray or Color-coded 
  • Conductor – 10, 14, 16, 20, 26, 40 

THHN – Solid 

  • Available Color – Black, White, Green, Red, Gray, Orange 
  • Available Gauge – 12 Gauge Only 

THHN – Strand 

  • Available Colors – Black, White, Green 
  • Available Gauge – 12 Gauge Only 

Select Length – The TOTAL length of wire required for a single assembly – This also applies for multiple wires. Select the length of each wire. 


The Estimator allows you to Add multiple wires.

Review your selection – if ready to proceed – click “NEXT STEP”


STEP 2 – Select the Number of Individual Wires 


Wire Harness Estimator

This section will include the TOTAL number of Individual Wires in your wire harness assembly



STEP 3 – Select Your Terminal 

Wire Harness Estimator

This section allows you the opportunity to select a specific manufacturer part number. Enter the manufacturer part number in the space provided and hit SEARCH. The product will populate into the estimate. 

If your specific part number is not available, you may select from the list of “house” parts below: 

  • Ring Terminal
  • Fork Terminal
  • Quick Connect/Disconnect Terminals
  • Ferrules Terminal

Select Quantity (for a Single Wire Harness) 


You may add multiple terminals and hit “ADD TO ESTIMATE” each time

Click “NEXT STEP” 


STEP 4 – Select Add-ons 


Wire Harness Estimator


  • Spiral Wrap
  • Expandable Sleeving 
  • Wire Ties 
  • Heat Shrink
  • Wire Labels 
  • Wire Label Flags 

Enter Length in inches 


You may add multiple Add-ons in this section. Please hit “ADD TO ESTIMATE” after each selection. 

Click “NEXT STEP” 


STEP 5 – Component Request 


Wire Harness Estimator

This section allows you the opportunity to add any additional components or helpful notes to help determine your estimate. 

Any items added to the “Components Request” section will NOT be added to the initial estimate. You will receive a separate email including the additional components to your wire harness assembly estimate. 


STEP 6 – Review and Submit 

Wire Harness Estimator


The Summary page allows you the opportunity to review your entries and make sure that everything looks accurate. 

Once you are satisfied with your selection simply enter your name and email address. You may also enter a project number to help keep track of each wire harness assembly estimate. 

Enter the correct number for the captcha and hit SUBMIT. 

You will receive your estimate within seconds in your email box. 



Please call 716-665-4176 at any step of the process with questions from 7-3:30 EST or email info@falconer-electronics.com. 

We are excited to offer this new program and welcome your constructive feedback. 

To learn more about these exciting products please connect on FacebookTwitterGoogle+, and LinkedIn,.