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.

Enclosure mode draws the convex outline round the packed wires - the arcs of the outer wires joined by straight tangents - and reports the whole area inside it as the total CSA: wires and gaps together, the cross-section an aperture or enclosure has to clear for the bundle to pass, with its width and height. It is a geometric hull of the wires at nominal OD, before any tape or lashing. Sleeving does not apply in this mode.

Wire CSA is the sum of the wires' cross-sections at finished OD - the same whatever the arrangement, and the figure conduit and raceway fill rules take as their numerator. Bundle CSA is the enclosing circle's area (the headline Ø restated as an area); in Enclosure mode that cell becomes the total CSA inside the outline. Fill is wire CSA over whichever envelope is shown.

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.