What are the difference between mil-spec wire vs hook up wire

You might have heard the terms hook up wire and mil-spec wire used interchangeably when it comes to the cables that are employed in the military – and beyond. However, the reality is that the two are not the same and hook up wire is usually totally unsuitable for military application. So, why has this confusion arisen and what’s the real difference between mil-spec wire and hook up wire?

Defining mil-spec wire and hook up wire

The reality is that there are a lot of similarities between the two – mil-spec wire is essentially a hook up wire but one that has a very different application and that’s why the two are not the same. But let’s start with the basics.

• A hook up wire. This is a cable with one conductor and is also sometimes called a ‘lead wire.’. A hook up wire is likely to be used in internal wiring across a broad spectrum of different devices and the application for it is wide. So, you might find a hook up wire, for example, being used as a power cable, control cable, a motor cable and a switchboard wire.
• Mil-spec wire. The similarity between hook up wire and mil-spec wire is that both have one conductor. Both types of wire are also required for the internal wiring of appliances although those appliances can be very different – and functioning in contrasting environments. All mil-spec wires, other than those that relate to data and communications, are essentially hook up wires and that’s often where the confusion between the two can arise.

So, what’s the difference?

Well, a mil-spec wire might work in a range of regular hook up wire applications but the average hook up wire would be unlikely to do the same in a mil-spec environment. That’s because mil-spec wires are hook up wires that have been designed for exceptional performance, such as improved temperature resistance or flex life. There are very specific standards that a mil-spec wire must meet in order to be approved for a military application and these are not standards that most average hook up wires could be designed for. What’s key to note is that regular hook up wire is not approved for military applications so it could never be used interchangeably in the way that the terms often are. In fact, in reality, regular hook up wire would fall far short of what is required to ensure the safety and reliability of wiring in a military application. Mil-spec wire could be used as a hook up wire in some specifications – and there are actually some types of non-premium mil-spec wire that would be a cheaper option than regular hook up wire. However, in the majority of cases it’s essential to keep the two separate.

Although we often use the terms hook up wire and mil-spec wire as if they are the same item, the reality is that they are not. Regular hook up wire is not approved for mil-spec application and simply wouldn’t perform under those conditions.