Copper Wire Drawing: This is the first step in power cord manufacturing. At room temperature, a wire drawing machine is used to pull copper through the orifice of one or multiple drawing dies. This process reduces the wire’s cross-sectional area, increases its length, and enhances its tensile strength.

Annealing of Single Wires: The copper wire is heated to a specific temperature to increase the ductility and reduce the strength of individual wires through recrystallization, meeting the requirements for conductive wire cores in cables. A key aspect of the annealing process is preventing oxidation of the copper wire.

Stranding the Conductive Core: To improve the flexibility of the power cord for easier installation, the conductive core is formed by twisting multiple single wires together. Stranding methods can be categorized into regular stranding and irregular stranding. Irregular stranding further includes bunch stranding, concentric stranding, and special stranding. To minimize the occupied cross-sectional area and reduce the overall dimensions of the power cord, a compacting process is often applied during stranding. This transforms the conventional round shape into semi-circular, sector-shaped, tile-shaped, or compacted round forms.

Insulation Extrusion: The primary method for applying insulation to power cords is through extrusion, forming a solid insulating layer.

Cabling for Multi-Core Power Cords: For multi-core power cords, to ensure a well-rounded form and minimize deformation, the insulated cores are twisted together into a circular configuration.