FULL BOOST Bundle Sizer

Geometry only. Each wire is drawn at its finished outer diameter (conductor plus insulation) taken from TE Connectivity control drawings. 55A (55A0111 / M22759/32, tin-coated copper, ETFE, 150°C) and 55M (55M0414, silver-plated alloy, ETFE, 200°C). Wires are packed by a deterministic nearest-fit routine and the bundle diameter is the smallest circle that encloses every wire. Real looms settle differently under tension and tape, so treat this as a tidy-pack estimate, not a guaranteed dimension.

Sleeving uses TE DR-25 (2:1 heat-shrink). A size is recommended that slides over the bare bundle and recovers tight onto it. Sleeved Ø is the bundle plus the size's recovered wall.

Slide-on is how much wider the sleeve is than the bundle before shrinking (ratio of expanded sleeve to bare bundle OD); more makes it easier to fit. It is also quoted as a radial clearance in mm per side.

Bundle / expanded is what percentage of the expanded sleeve the bundle fills. The tool caps this at 80% by default, to leave room to slide the sleeving over the bundle.

Recovery is how far through its shrink range the sleeve travels to grip the bundle: 100% means it recovers fully onto the bundle (bundle at the recovered ID), less means it grips before fully recovering.

Fill is the summed wire OD area divided by the enclosing-circle area. It's a rough measure of how tightly the bundle packs.