Understanding Current Carrying Capacity from AWG: A Key Guide to Wire Harness Selection

In custom wire harness projects, the most frequent client question is:"What wire size should I choose?"

This "size" refers to AWG (American Wire Gauge) — a standardized system reflecting conductor diameter, which directly determines a wire’s current-carrying capacity, safety margin, and thermal performance.

1. Basic Relationship Between AWG and Conductor Size
Lower AWG numbers indicate thicker wires with higher current capacity. Examples:

AWG 28 ≈ 0.08 mm² — Ideal for low-current signal lines

AWG 20 ≈ 0.52 mm² — Suitable for mid-range power

AWG 14 ≈ 2.07 mm² — For high-power systems

2.Current Carrying Capacity Reference (PVC Single Core)

Critical Notes:

Actual current capacity varies significantly with cable length, ambient temperature, insulation material, bundle density, and installation method.

Tabulated values are conservative estimates. Always verify with IEC/UL standards or manufacturer datasheets for specific applications.

3. How to Choose the Right AWG for Your Application?

Long-distance runs: Require thicker conductors to minimize voltage drop.

High-temp/dense layouts: Demand additional safety margins.

Consumer electronics: Typically use AWG 28–24.

Industrial/vehicle systems: Prefer AWG 20–16.

4. Services from Shenzhen Era WingShing Electronics Co., Ltd.

We deliver custom wire harnesses from AWG 30 to AWG 16 with multiple insulation options:

PVC | Silicone | PE | TPU

UL-certified wires

Standard & custom crimping

Precision connector assembly

Current values in the image are rounded approximations (1 decimal), while original table data uses higher precision (1-2 decimals); always refer to certification standards or manufacturer specs for actual selection.