Wire Wrapping: The Forgotten Art of Reliable Electrical Connections

Wire wrapping has been a go-to method for making electrical connections in prototyping since its inception over 60 years ago. Despite being largely replaced by printed circuit board (PCB) technology, wire wraping remains a reliable and resilient alternative, especially for hobbyists and those who prefer the tactile and versatile nature of this technique.

The Advantages of Wire Wrapping

Compared to other methods, such as breadboard connections, wire wrapping offers several advantages that make it a favored choice for both professionals and hobbyists. One of the most significant benefits is the reliability and longevity of the connections it provides. Unlike breadboards, which can often develop loose or failed connections over time, wire wrapping ensures that connections remain secure and stable, even over extended periods.

Another advantage is the durability of wire wrap connections. In my experience, complex wire wrap prototypes have continued to function properly even decades later. The tight and secure nature of these connections means that the wires are less likely to come undone or pull out, providing peace of mind during long-term projects. Furthermore, the ability to easily undo connections makes wire wrapping an invaluable tool for troubleshooting and making modifications.

Wire Wrapping in Action

I fondly recall using wire wrap in the 1980s and 1990s, particularly in complex electronic projects. I have even used it in some modern hobby electronics, where the versatility and flexibility of wire wrapping shine through. For instance, in the image below, you can see a part of a dart marker where a Nano is wire wrapped onto the PCB. The wraps not only hold it in place but also provide a reliable electrical connection. Discrete components are soldered to the board and connected to wire wraps via wrap pins, allowing for a dense and organized layout.

Below is an example of a completed wire wrap project, showing the Nano and its contacts connected through wire wrapping.

The Evolution of Wire Wrapping

Wire wrapping was developed as a highly precise and reliable method for connecting components in the mid-20th century. While it was used extensively in the 1980s and 1990s for prototyping, it was eventually overshadowed by the advent of PCB technology. Despite becoming obsolete for mass production, wire wrapping has found a niche in the world of custom and one-off projects.

Wire wrapping involves wrapping fine wires tightly around stakes or pins to form electrical connections. This technique is particularly well-suited for discrete components and specialized sockets that allow for easy connections. The use of sockets with wire wrap pins ensures that connections are clean and tight, often lasting for decades without issue.

Modern Use and Future Outlook

While wire wrapping may seem like an outdated technology, it still holds value for hobbyists and those working on custom projects. The technique has been used to build entire computers, such as the DEC minicomputer CPU, demonstrating its versatility and reliability.

Advancements in PCB manufacturing have made it more affordable and accessible, even for complex projects. As a result, wire wrapping is often seen as a method that is completely obsolete. However, for one-off prototypes and custom devices, wire wrapping remains a valuable and reliable tool in the electronic prototyping arsenal.

Conclusion

In conclusion, wire wrapping is a highly reliable method for making electrical connections, offering numerous benefits over other connection methods. Despite its decline in use for mass production, it remains a valuable technique for hobbyists and those who appreciate the tactile and versatile nature of this process.

Whether you are building a complex prototype, working on a hobby project, or simply looking for a reliable connection method, wire wrapping is worth considering. Its durability, reliability, and ease of modification make it a timeless tool in the world of electronics.