Wire Gauge

Tips for Choosing the Correct Gauge of Wire for the Job

Have you been looking into a wiring project? Do you know what gauge of wire is best suited for your needs? Our tips can help you in the choosing process of wires!

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**

1: What type of project are you doing?

There are many different types of wiring projects. Depending on whether you are working on home wiring or building your own robot, there is a difference of what type of wire is required. For example, some projects include:

  • Home wiring
  • Robotics
  • Computers
  • Vehicles

2: How much space do you need for wiring?

To begin with different housings for different projects will vary in size. Due to the wire size, the space needed to house them will vary. If you think about a light switch, some have a single switch and therefore only need enough room for the wires of that one switch. However, there are light switches that have multiple switches. Therefore, the space required for the wiring of a multi-switch receptacle is larger than that of a single switch receptacle. In order to do a job properly, you need to be aware of how much space you have to work with and really need. If you are working on home wiring that requires a larger current as opposed to a robot that requires less current the space needed is different because the wire size will be different.

3: How are wire gauges calculated?

Especially relevant is the fact that as wire increases in physical width, the gauge of that wire will decrease in numerical value. While this does seem backward it’s really not. Due to the wire drawing process, the number of operations that it takes to get it to that physical size is the numerical gauge of a wire. As a result, gauges are larger or smaller than the physical size.

Wire Gauge

4: What are large and small gauged wires used for?

There are also many different gauges of wire. Consequently, they have many different uses.

Uses for some smaller gauges (larger physical sizes) of wire:

  • Electrical lines (like those you see outside attached to power lines)
  • Heavy duty automobiles like trains, larger armored trucks
  • Home wiring

Uses for some larger gauges (smaller physical sizes of wire):

  • Computers
  • Radios
  • Phones
  • GPS
  • Mp3 player
5: How much amperage do you require?

There are different factors that determine the required amount of amperage:

  • Amperage= Wattage/Volts
  • What current do you need for your project
  • Where the wire is going
  • Where the wire is coming from

In addition to these tips you can learn more about wire gauges by looking back to our previous blog Why Do Wire Gauge Sizes Seem To Work Backwards?

In conclusion, the chart below will be helpful in deciding which wire is appropriate for your specific job.

AWG Cable/ Conductor Size Chart

AWG Diameter 
[Ohms / 1000 ft]
[Ohms / km]
 Max Current 
Max Frequency
for 100% skin depth
 0000 (4/0)0.4611.6841070.0490.16072302125 Hz
000 (3/0)0.409610.40384850.06180.202704239160 Hz
00 (2/0)0.36489.2659267.40.07790.255512190200 Hz
0 (1/0)0.32498.2524653.50.09830.322424150250 Hz
10.28937.3482242.40.12390.406392119325 Hz
20.25766.5430433.60.15630.51266494410 Hz
30.22945.8267626.70.1970.6461675500 Hz
40.20435.1892221.20.24850.8150860650 Hz
50.18194.6202616.80.31331.02762447810 Hz
60.1624.114813.30.39511.295928371100 Hz
70.14433.6652210.50.49821.634096301300 Hz
80.12853.26398.370.62822.060496241650 Hz
90.11442.905766.630.79212.598088192050 Hz
100.10192.588265.260.99893.276392152600 Hz
110.09072.303784.171.264.1328123200 Hz
120.08082.052323.311.5885.208649.34150 Hz
130.0721.82882.622.0036.569847.45300 Hz
140.06411.628142.082.5258.2825.96700 Hz
150.05711.450341.653.18410.443524.78250 Hz
160.05081.290321.314.01613.172483.711 k Hz
170.04531.150621.045.06416.609922.913 k Hz
180.04031.023620.8236.38520.94282.317 kHz
190.03590.911860.6538.05126.407281.821 kHz
200.0320.81280.51810.1533.2921.527 kHz
210.02850.72390.4112.841.9841.233 kHz
220.02540.645160.32616.1452.93920.9242 kHz
230.02260.574040.25820.3666.78080.72953 kHz
240.02010.510540.20525.6784.19760.57768 kHz
250.01790.454660.16232.37106.17360.45785 kHz
260.01590.403860.12940.81133.85680.361107 kHz
270.01420.360680.10251.47168.82160.288130 kHz
280.01260.320040.08164.9212.8720.226170 kHz
290.01130.287020.064281.83268.40240.182210 kHz
300.010.2540.0509103.2338.4960.142270 kHz
310.00890.226060.0404130.1426.7280.113340 kHz
320.0080.20320.032164.1538.2480.091430 kHz
330.00710.180340.0254206.9678.6320.072540 kHz
340.00630.160020.0201260.9855.7520.056690 kHz
350.00560.142240.0163291079.120.044870 kHz
360.0050.1270.0127414.813600.0351100 kHz
370.00450.11430.01523.117150.02891350 kHz
380.0040.10160.00797659.621630.02281750 kHz
390.00350.08890.00632831.827280.01752250 kHz
400.00310.07874 0.00501104934400.01372900 kHz

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!

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

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**   

Made in USA: “All or Virtually All”

Many small manufacturers in the U.S. struggle to determine if the product that they assemble, manufacture or produce truly qualifies for the label “Made in USA” or “American-Made”.

The world is shrinking fast. Competition is fierce. The Internet has escalated the global economy. Manufacturers are eager to comply with the standards as long as it is consistent and well defined. Yet, some companies are too eager to capitalize on the “Made in America” logo. Having a “Made in America” standard helps weed out companies that are simply throwing a sticker on a product that is imported from another country.

Doing a Google search for “Complying with Made in USA produces 854,000 results. The #1 ranking is a link to the Federal Trade Commission website titled: Complying with the Made in USA Standard. The page offers a link to a pdf that dates back to 1998. Traditionally, the Commission has required that a product advertised as Made in USA be “all or virtually all” made in the U.S.

What Does “All or Virtually All” Mean?

“All or virtually all” means that all significant parts and processing that go into the product must be of U.S. origin. That is, the product should contain no — or at least negligible — foreign content.

Manufacturers may think that they are truly “Made in USA” with all parts being purchased from domestic suppliers. When in fact, certain parts or raw material could have very well been imported from a foreign country unbeknownst to the manufacturer. Even if you purchase raw material, parts, and components from a domestic distributor, those products may have originated in another country.

Even when a manufacturer has the best intentions and would eagerly purchase domestic goods, they are simply not always available. Specific countries, geographical regions, climates, etc lend to certain products being produced in those areas. You may have a product that you assemble in the U.S. with raw components purchased from various countries. In many cases, it is just not cost-effective to produce certain products in the U.S. Basic economics says that supply and demand control a market. Price is typically a key ingredient. If a product cannot be produced at a price that a customer is willing to pay, then it is going to be extremely challenging to create a viable let alone a sustainable company. Well at this point you are thinking, thank you Captain Obvious.

The responsibility falls on the manufacturer to have a clear understanding of where all parts and components originated from. Ignorance is not a reliable excuse or defense. Some companies have found themselves in trouble by making a false claim even when they had the best intentions.

For example, Maglite, a California lighting manufacturer made national news by losing a lawsuit over false Made in USA claims. Maglite is an amazing American entrepreneur success story. It boiled down to a microchip and a rubber seal that originated overseas that cost the owner thousands of dollars in legal defense and still lost the case.

Industrial Magnets

Industrial Magnets

Heavy Duty Industrial Magnets

Falconer Electronics offers its signature line of Heavy Duty Industrial Magnets exclusively online. Customers love using our magnets in industrial settings. Each magnet is produced with a coating that is corrosion and temperature resistant. Falconer Electronics Signature Industrial Magnets are exclusively produced in the USA at our manufacturing facility. Also, we back up every magnet with our 1 Year Product Guarantee.

Magnets are produced from raw magnet material and then enclosed in epoxy or urethane. The raw material of these Heavy Duty Industrial Magnets consists of either ceramic or neodymium.

Neo what, you ask? Let’s dig a little deeper into each raw magnet. We turn to the Magnet Materials Producers Association and the Standard Specifications for Permanent Magnet Materials for a thorough explanation:

Ceramic Magnets

“Ceramic magnets are generally formed by a compression or extrusion molding technique which is then followed by sintering. Finish grinding or shaping, when necessary for better control of dimensions, is normally done by using diamond grinding wheels. The material to be molded can be in either a dry powder or wet slurry form. Magnetic performance can be increased in a preferred direction by applying a magnetic field in that direction during the molding process.”

Neodymium Magnets

“The rare earth magnet alloys are usually formed by powder metallurgical processes. The magnetic performance of all grades is optimized by applying a magnetic field during the pressing operation, thus producing a preferred direction of magnetization. Pressing and aligning techniques can substantially vary the degree of orientation and the residual induction (Br) of the finished magnet.”

Magnetic Work Lights 

These magnets have multiple uses. All Falconer Electronics Magnetic Work Lights come equipped with our rugged and durable magnets.  The line of Magnetic Work Lights includes Fluorescent Lights, Magnetic Spot Lights, and Magnetic Trouble Lights.

Magnetic 13 Watt Fluorescent Lamp w/25' Cord Magnetic 5-1/2" Spot Light with 25' Cord Magnetic Trouble Light with Metal Guard and 50' Cord

Industrial Magnets Shapes and Sizes 
Our Industrial Magnets have an outstanding work ethic! Reliable, dependable, and willing to tackle any project. They never oversleep or call in sick either. Interested in having these magnets join your team? Click here.
Below are class photos of this year’s roster:
M-1 Stock Magnet - 28 lb Pull #4C Stock Magnet - 45 lb Pull


Magnetic Pickup Tools

Falconer Electronics’s Magnetic Pickup Tool is ideal for the retrieval of ferrous metal materials. This durable retrieval tool is produced with a Heavy Duty Industrial Magnet that is attached to a 48″ wooden handle with die cast zinc clamps.

Magnetic Pickup Tool


Thank you for reading our post on Falconer Electronics Signature Line of Industrial Magnets.

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


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.

Positive Work Environment

Never bet against a company dedicated to creating a Positive Work Environment. A deep commitment to innovation combined with maintaining a healthy entrepreneurial spirit are driving forces that can enable a small business to achieve great heights. Having fun while at work makes an enthusiastic workplace and a dynamic team.

A Positive Work Environment Increases Productivity 

According to the Harvard Business Review, a Positive Work Environment is more productive. In the article, “Proof That Positive Work Cultures Are More Productive“, the authors share that work stress significantly reduces the health and productivity of employees. Absenteeism, disengagement, and lack of loyalty all dramatically increase costs and hurt the bottom line. 

Deliberate actions allow a company to create a dynamic culture, which includes ambition, competitiveness, creativity, flexibility, enthusiasm, and initiative. Combining these efforts with the ability to take risks and bear responsibility is a winning formula. Many large companies founded by visionary leaders begin as a start-up enterprise and eventually evolve into an industry powerhouse.

Positive Work Environment

 Southwest Airlines Positively Outrageous 

Ever fly on Southwest Airlines and have a stewardess serenade the audience while giving out the flight instructions? Southwest Airlines has produced 40 straight years of profits in an industry that continuously suffers massive financial losses and has been littered with bankruptcies over the years.

Southwest lives by a daily mantra to never accept status quo tracing back to its founder, Herb Kelleher. He pointed out that it is extremely difficult for a competitor to imitate a company’s success. According to an article in Forbes, Kelleher states,“They can buy all the physical things. The things you can’t buy are dedication, devotion, loyalty—the feeling that you are participating in a crusade”.

Whistle While You Work  

Taking a tour of Falconer Electronics displays hard working Americans dedicated to producing high-quality commercial outlet stripsprinted circuit boards, and wire harnesses. You will hear machines running, trucks rumbling, computers cranking and other sounds of great products being produced.

More importantly, you will hear lots of laughter. Our team has a wicked sense of humor. You can always hear someone laughing over something hysterical. Either a goofy event that occurred over the weekend with a friend or family member. A crazy pet story brings a good laugh as well around here. Work hard and laughing harder is our mantra!

Our office is located near Wegmans Food Markets which provides an excellent role model for small businesses. Fortune ranked Wegmans as the #2 Best Companies to Work For in 2017. This year marks the 20th straight year landing on the Fortune 100 Best Companies to Work For list. Wegmans institutes a thriving Positive Work Environment that combines fun with professionalism to deliver outstanding customer service. This winning formula proves hugely successful and profitable with Wegmans celebrating 100 years in business. 
Thank you for reading our post on a Positive Work Environment.
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