Cheapest Wire-Wrapping Tool




Introduction: Cheapest Wire-Wrapping Tool

About: I am Electronic Visualization Artist. I look at things through the Looking Glasses.

When we are dealing with these sensors:

•Flex Sensor
•Flexiforce Pressure sensor
•Force Sensitive Resistor
•HotPot Membrane Potentiometer
It really hard to solder their leads to PCB. Because  these sensors made out of plastic, and they melt easily.

One solution is to use wire wrap (30AWG) instead of solder. You also need the wire-wrapping tool to do the job.
There are varieties wire-wrapping tools available, and the cost is varies from $6 to $29 or more. Which is considered expensive when we only want to use this wire-wrapping tool to do the job may be only once or twice.

I was working on a project that I used Force Sensitive Resistors, and I found the cheapest, efficient wire-wrapping  tool to wire-wrap the 30AWG wire to those Force Sensitive Resistors. And here it is, may I introduce to you, a "paper clip".

Here is the project that I utilized these FSRs and this wire-wrapping tool


Electronic Component of your choice to be wire-wrapping (in this case, Force Sensitive Resistor)
Paper Clip
30AWG wire wrap
Wire Stripper
Heat Shrink Tube

Paper clips are in different shapes and sizes. My choice was the typical paper clip. I used an 1-1/4 inchs in length. The diameter of this paper clip seem to fit perfectly well with the leads of Force Sensitive Resistors.

Set the wire stripper's gauge to suit the size of 30AWG wire.
Strip the 30AWG wire wrap about 3/4" to 1" away from the end.

1.Spread out one end of the paper clip.
2.Wrap and tight  the stripped 30AWG wire wrap on to the spreaded out end of paper clip, I did about 10 turns.
3.Squeeze the wire wrap in together.
4.Slide them out of the paper clip.
5.Cut the other end of the wire wrap to the require length
6.Repeat step 2 to 5 until you have enough to use (I made eight of them for four Force Sensitive Resistors)

Insert these prepared wire wraps to the component leads (here Force Sensitive Resistors)
Use your thumb and index finger (or small needle nose pliers) to squeeze the loop tight to the component leads.
Insert the Heat Shrink Tube long enough to cover the joint.
Use hair dryer or heat gun to shrink the tube.

That's it!  We are done!

This method is not limited only to the components with the plastic body. You could use this "paper clip"  tip to wire wrapping any components.

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    3 Discussions


    6 years ago on Introduction

    Wire wrapping tools are awesome, but too damn expensive! thanks!


    7 years ago on Introduction

    If you use a heat sink, you won't have problems with melting the plastic. Also, if these bend at all, wire wrap wire is eventually going to snap. Use a fine stranded wire instead. My favorite is 80 conductor IDE cable.

    A heat sink could be nothing more than an aligator clip with a piece of solid 14ga copper wire attached. Just something with some thermal mass to draw the heat away from the plastic.


    Reply 7 years ago on Introduction

    Thanks fo the info. I will keep that in mind.