Electrical wires and cables are conductive materials used to transmit power between electrical devices. Simply, they are the “road” for electricity with different designs used in different scenarios. From home decoration to industrial equipment, as long as you need to use electricity, there are wires and cables. In this blog, we will have a detailed breakdown of the electrical wire cable, including the differences between wire and cable and their major types, so as to give you a wise insight when choosing electrical wire and cable for your projects.
In practical electrical systems, we’ll find that the terms wire and cable are used interchangeably, but they are not the same. Though they are structured with conductor and insulation, they vary in their design, construction, and applications.
| Feature | Electrical Wire | Electrical Cable |
| Conductors | Single | Multiple, bundled together |
| Insulation | 1 layer | Over 2 layers |
| Protection | Only insulation | Jacket, shielding, fillers |
| Flexibility | Weaker | Stronger |
| Common Uses | Home, commercial buildings | Industrial, underground |
| Examples | THHN wire, bare copper ground wire | USB, HDMI, power cables |
Electrical wires are simpler and consist of solid or stranded single conductors with an insulation layer for electrical contact prevention. It is usually used for homes, commercial buildings, and more.
Electrical cables are more complex with multi-wire bundles, insulation, and protection, making them more durable for demanding environments. That’s why electrical cables are always used in industrial, underground, or high-voltage uses.
Understanding the different types of electrical wires and cables is important to choosing the right wire or cable for your project. Next, we will introduce the types of electrical wire cable as well as the respective key uses of different types.
Electrical wire types vary based on different electrical wire uses, conductor materials, and insulation. Here we classify electrical wires according to their conductors and insulation.
The wire conductors include solid ones and stranded ones when it comes to conductor design, and have copper and aluminum types in materials.
Solid wires are those wires with single and solid copper or aluminum strands. They are cost-effective and durable for permanent installations like circuit boards. Though solid wire has a higher current capacity, it is less flexible hard to bend, and easier to break.
Multiple thin conductors of stranded wires are twisted or braided together, making them more flexible and easier to route in applications with frequent movement.
Copper wires are the most widely used conductor thanks to their great conductivity and resistance to corrosion. With minimal energy loss and effective current carrying, copper wires are the perfect selection for residential wiring, electronics, and automotive applications.
Aluminum wire, though less conductive than copper, is lighter and more cost-effective, making it common in power transmission lines and large-scale electrical projects. One drawback is that aluminum is easier to oxidize and needs specialized connectors to prevent fire hazards and loose connections. However, the modern AA-8000 Series Aluminum version solves it with better performance in oxidation.
The insulation protects the conductor and also determines the wire’s temperature rating, flexibility, and environmental resistance. Here are some common types with possible electrical wire prices and key uses.
| Type | Material | Temp. Rating | Moisture Resistance | Cost Level | Key Uses |
| THHN | PVC + Nylon coated | 90°C (194°F) dry | Good | Budget-friendly | Conduit wiring (residential/commercial) |
| THWN | PVC (waterproof grade) | 75°C (167°F) wet/dry | Excellent | Moderate | Wet/damp locations, outdoor |
| XHHW | XLPE (Cross-linked Polyethylene) | 90°C (194°F) wet/dry | Excellent | Moderate to High | Industrial power, solar farms |
| MTW | PVC or TPE (oil-resistant) | 90°C (194°F) dry | Good (oil-resistant) | Medium to High | CNC machines, factory automation |
| PTFE | Teflon® (FEP/PTFE) | 250°C (482°F) | Excellent | Premium | Aerospace, military, extreme heat |
| TFFN | PVC + Nylon coated | 90°C (194°F) dry | Fair (dry only) | Moderate | Lighting fixtures, appliances |
THHN is one of the most common types of electrical wire insulation in building wiring and industrial applications due to its effective price. This is a thermoplastic((PVC + Nylon) insulated wire with a nylon coat that can withstand high heat and provide additional protection. THHN is rated for 90℃, making it ideal for fry and weathering environments, such as inside conduits for commercial and residential wiring.
THWN is the variant of THHN which is water-resistant and can also withstand 75°C in wet conditions, making it preferred for both indoor and outdoor, especially wet locations where is exposed to moisture. It is also a good choice for households, commercial buildings, and outdoor applications.
XHHW has thermoset insulation with XLPE(cross-link polyethylene) rather than thermoplastic, which has better thermal and chemical stability than PVC. It is durable and resistant with a rate of 90°C in both dry and wet conditions, endowing it with a longer lifespan in industrial and commercial power distribution.
PTFE, also known as Teflon®, is popular for its capacity to handle extreme temperatures. It can withstand temperatures up to 250°C, making it widely used in aerospace, military, and high-heat industrial environments. What’s more, non-stick and low-friction features also allow it to be used for wire assemblies that need smooth movement. Great performance and specialized manufacturing processes also make it extremely expensive.
Insulated with flexible PVC or Thermoplastic Elastomer (TPE), MTW is resistant to oils, coolants, and abrasion. This also makes it essential for machinery and automation systems like CNC machines and factory automation. Rated 90°C which makes it suitable for high heat environments and high flexibility also allows it to withstand constant movement to to be used in robotic arms.
TFFN characterizes stranded copper conductors, PVC insulation, and thin nylon jacket. Enhanced flexibility and durability make it a go-to electrical wire for lights like pendant lights, HVAC, and various appliances. It is not very suitable in wet locations and more feasible for dry environments.
Electrical cable types are more complicated based on different structures and applications. Here are some common types of electrical cables.
Non-metallic building cables, or Romex™ and NM cables, feature with flexible plastic sheath with two to four wires and a bare wire for earthing. They are cost-effective and easy to install, making them particularly used for underground or outdoor use where are free from moisture and heat sources. They are the most commonly used electrical wire for houses, like lighting applications and appliances.
UF or underground feeder cables are designed for direct burial with moisture-resistant jackets, protecting them from soil and weather damage. Such characteristic makes it ideal for wet areas such as gardens, open-air luminaires, pumps, etc.
Also known as armored or BX cables, metal-sheathed cables are armored with flexible metal sheathing, providing superior physical protection in harsh environments. They are usually used for outdoor applications and high-stress installations, which makes them relatively expensive.
Coaxial (sometimes helium) cables are named because there are the same geometric axis in the two inner shields. Featuring central conductors surrounded by shielding, such cables are usually used to transmit high-frequency signals for TV and internet and connect video equipment. Price varies based on models.
With more than 1 insulated conductor under one sheath, the multi-conductor cables perform well in power or signal transmission in control systems. Their different varieties are used in different industries, for example, the audio multi-core ‘snake’ cables used in the music industry.
By using 2 twisted conductors to reduce interference, the non-insulated wire is suitable for signal transmission and video applications. They are usually applied for telephony, security cameras, and data networks, and the types with copper or solid copper cores are prevalent for indoor use due to their flexible feature.
HDMI cables are rubber digital cables which often used to transmit high-definition audio/video signals between devices. It is affordable and has different connector types for different uses, such as Type A/B is defined in the HDMI 1.0 specification.
Speaker cables are used for electrical connections between loudspeakers and audio amplifiers. They are typically designed with oxygen-free copper (OFC) conductors, which are often thicker than that of other wires.
Category 5e cables, or cat 5e are mainly used in networks and internet facilities. Comprised of twisted pairs of wires that minimize interference, cat 5e enhances reliability and data transmission. They are very affordable and super easy to install.
Twisted pair cables are twisted conductors together to minimize the interference from other devices. This cable is the optimal choice for networking and telephone lines in that it includes both shielded (STP) and unshielded (UTP) variants for data transmission, and is effective for signal transmission in short and and medium distances.
USB cables or Universal Serial Bus, are the cables used for power connecting, charging, and file transfer between devices like computers, and smartphones. Only insert the devices, USB cables are easy to use without any special tools or settings. The types of USB cables include Type A, Type-B, micro-USB, and more.
| Cable Type | Key Features | Typical Use | Price Range |
| Non-Metallic Sheathed (NM) | PVC sheath, grounding wire, indoor use | Residential wiring | Low |
| Underground Feeder (UF) | Moisture-resistant, direct burial | Outdoor circuits | Moderate |
| Metal-Sheathed (AC/MC) | Flexible metal armor, crush-proof | Industrial/commercial | Moderate–High |
| Coaxial (RG-6/RG-59) | Shielding for signal integrity | TV/internet | Low–Moderate |
| Multi-Conductor | Multiple insulated wires | Control systems, audio | Low–High (varies) |
| UTP (Cat 5e/6) | Twisted pairs, EMI reduction | Ethernet networks | Low |
| HDMI | Digital AV transmission, plug-and-play | Home theaters | Moderate–High |
| Speaker Cables | Thick gauges, oxygen-free copper options | Audio systems | Low–High |
| Cat 5e | Twisted conductors | Networking | Low |
| Twisted Pair (STP/UTP) | STP + UTP | Data/telecom | Low (UTP)–Mod (STP) |
| USB (Type-A/C/micro) | Power + data transfer, device charging | Electronics | Low–Moderate |
Understanding electrical wire cable types is basic to choosing the electrical wire cable for your wiring project to ensure sound performance, safety, and energy efficiency. Choosing the right wire and cable in electrical systems also needs a professional team. At Vocson, we provide high-quality, certified wires and cables tailored to your needs, whether electrical cables for house or electrical cables for medical, Vocson provides you with smart and efficient power solutions for your perfect electrical wires and cables.
Related Reading
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