AWG Wire Thickness Question

Smaller number is thinner when using the measurement unit "gauge"

I'm curious as to why. Maybe Athena can tell us more.

In AWG (American Wire Gauge), the smaller the number, the thicker the wire.

So:

• 10 AWG = thicker than 14 AWG
• 14 AWG = thinner than 10 AWG
• 18 AWG = thinner still

Quick rule

• Lower gauge number = thicker wire
• Higher gauge number = thinner wire

Why it works that way

AWG is a legacy sizing system, so the numbering runs opposite of what many people expect. It’s common in robotics, automotive, and power wiring.

For your LED project

If it’s a small LED project, 14 AWG is usually much thicker than needed unless you’re carrying a lot of current or running a longer power line. For typical LEDs, people often use something more like:

• 22-26 AWG for signal / low-current wiring
• 18-20 AWG for modest power wiring
• 14 AWG for heavier power distribution

If you’re wiring something in an ARC project with an EZB, the wire choice depends on the load:

• Servos / motors / higher-current power: thicker wire
• LEDs / sensors / signals: thinner wire is usually fine

If you want, I can help you pick the right AWG for your exact LED setup if you tell me:

1. LED type
2. Voltage
3. Current draw or resistor value
4. Wire length

thank you bolt

so am asking cause the 14 AWG doesn't go into the female dc jack plug . so i need maybe 16 AWG .

Yes - if the 14 AWG wire won’t physically fit into the female DC barrel jack plug, then moving to a smaller gauge number is not the fix.

Important point

• 14 AWG = thicker
• 16 AWG = thinner
• But many DC barrel jack terminals are only designed for small stranded wire, often around 18-22 AWG

So if 14 AWG doesn’t fit, 16 AWG may still be too large depending on the connector.

What to do

Check the plug’s wire terminal spec if you can. Many of those adapters accept something like:

• 18 AWG
• 20 AWG
• 22 AWG

Best practical options

• Use a smaller gauge wire like 18 AWG or 20 AWG
• Or use a barrel jack adapter / pigtail
• Or splice from thicker wire to a short section of thinner wire near the connector

For an ARC / EZB project

If this is powering an EZB or another robot component, the correct wire size depends on current draw and wire length. For many small robot power connections, 18 AWG is a common starting point.

Quick check

If you want, send me:

• the exact barrel jack size if you know it
• the power supply voltage
• what device you’re powering

and I can help suggest the right gauge and connector style.

@Nomad ,

Athena is correct: In AWG (American Wire Gauge), the smaller the number, the thicker the wire.

Quote:

So: 10 AWG = thicker than 14 AWG 14 AWG = thinner than 10 AWG 18 AWG = thinner still

Quote:

16 AWG (American Wire Gauge) copper wire typically has an ampacity of 10 to 13 amps for standard, continuous residential or long-run applications, though it can handle up to 18 amps in 90C, short-run, or open-air scenarios. It is commonly used for light-duty extension cords, LED lighting, and low-voltage

That’s right - smaller AWG number means thicker wire, and for LED projects you usually don’t need anything as thick as 14 AWG unless you’re carrying significant current.

A couple of practical notes:

• 14 AWG is fairly thick and often won’t fit small DC barrel jack terminals.
• 16 AWG is thinner, but it still may be too large depending on the connector.
• For many small LED / low-power robot connections, 18-22 AWG is much more common.

For your barrel jack

If the wire is too large for the plug, the best fix is usually:

1. Check the connector’s wire gauge rating
2. Use a smaller wire gauge that fits
3. Or use a pigtail / adapter and splice to thicker wire farther away from the plug

For an ARC / EZB project

If this is powering something in an ARC robot project, wire choice depends on:

• current draw
• wire length
• connector type
• whether it’s just LEDs or higher-load devices like servos/motors

If you tell me the exact device you’re powering and the barrel jack size, I can suggest a better AWG range for it.

hi dave

i wanted to make a short dc jack to dean female for the new inmoov ez robot head . i already made the space for it . thanks

That looks like a DC barrel jack mounted nicely in the head, and a Deans connector for the power lead is a good choice for a compact robot like an InMoov-style build.

Wire gauge recommendation

For a short DC-jack-to-Deans female pigtail, I would usually suggest:

• 18 AWG as a very safe general choice
• 20 AWG if the current is modest and the run is very short
• 16 AWG only if the connector physically accepts it and you expect higher current

Since you already found that 14 AWG is too thick, I’d start by trying 18 AWG stranded wire. It’s flexible and usually fits small barrel jack connectors much better.

Why 18 AWG is often the sweet spot

For robot head wiring:

• it’s thinner and easier to route
• it still handles reasonable current
• it fits many small connectors better than 14 or 16 AWG
• it’s a common choice for short power leads in robotics

A couple of cautions

• Make sure the polarity matches between the barrel jack and the Deans connector
• If the head has servos or other loads, check the total current draw
• Use stranded wire, not solid wire, for movement and vibration

ARC / EZB note

If this is powering an EZB or ARC robot project, the main concern is not just the connector fit - it’s also preventing brownouts from servo load. Synthiam has a good power reference here:

• Battery and Power Supply:
  https://synthiam.com/Support/troubleshooting/Battery-and-Power-Supply

And for general robot power planning:

• Choose a Power Type:
  https://synthiam.com/Support/Get-Started/how-to-make-a-robot/power

My practical recommendation

For what you showed, I’d try:

• 18 AWG stranded first
• if it’s still too thick, go to 20 AWG
• keep the wire as short as practical

If you want, I can help you pick the exact gauge based on the power supply voltage, expected current, and whether that head is driving servos only or also lights/audio.