Manufacturer · Fashion & Home Accessories
Cord end sizes are determined mainly by the inner diameter, which must be equal to the diameter of the sealed end of the cord or very slightly larger. For round cords on clothing, cord ends with an inner diameter of about 3 to 6 mm are most common, for shoelaces about 2 to 5 mm, and for flat cords the width is what matters. The length of the cord end is usually about 15 to 30 mm, depending on the product and style.
Which cord end sizes matter
- Inner diameter – the opening the cord goes into. This is the key parameter.
- Outer diameter – determines whether the cord end passes through the eyelet or channel and how it looks relative to the cord.
- Length – affects the grip and the look; a longer cord end grips more cord.
- Hole depth – for solid cord ends, how far the cord can go in.
- Width and thickness – for flat cord ends, instead of diameter.
How to measure the cord
The most common mistake is measuring the cord by eye or from the supplier's description. Braided cords narrow under tension and widen at rest, and after sealing the end may become narrower or wider.
- Use a calliper, not a ruler.
- Measure the cord in a relaxed state, without tension, at several points.
- Seal the end as it will be in production and measure again.
- For flat cords, measure the width and thickness.
- Record the largest value – the cord end is chosen based on it.
If in doubt, send the manufacturer a few centimetres of the actual cord. This is the surest way to get the exact size.
Guide table
| Product | Cord | Inner diameter of cord end | Usual length |
|---|---|---|---|
| Sweatshirt, hood | Round, about 4–6 mm | about 4–6 mm | about 20–30 mm |
| Joggers, waistband | Round or flat, about 3–5 mm / 8–12 mm | about 3–5 mm or flat | about 15–25 mm |
| Shorts, swimwear | Thin round, about 2–4 mm | about 2–4 mm | about 15–20 mm |
| Jacket, anorak (hem) | Elastic cord, about 2–4 mm | about 2–4 mm | about 15–25 mm |
| Shoelaces | Round about 2–5 mm, flat about 7–10 mm | about 2–5 mm or flat | about 15–20 mm |
| Drawstring bag, backpack | Thick round, about 5–8 mm | about 5–8 mm | about 20–35 mm |
The table is a guide. The actual size depends on the specific cord and type of cord end.
Tolerance and attachment type
Crimp-on cord ends
The inner diameter before crimping can be slightly larger than the cord, because the metal contracts around it when crimped. If the difference is large, the cord end deforms and does not look good. If it is small or negative, the cord does not go in or gets cut.
Glue-on cord ends
Here a small clearance is needed for the adhesive – usually tenths of a millimetre. An opening that is too wide leads to excess glue and a crooked cord end.
Screw or clip cord ends
They have an internal clip that grips the cord within a specified range. The manufacturer states the minimum and maximum diameter they are designed for.
Outer diameter and eyelets
If the cord has to pass through eyelets or be removed from the channel for washing, the outer diameter of the cord end must be smaller than the inner opening of the eyelet. If the aim is the opposite – for the cord not to come out of the channel – choose a wider cord end or add a cord stopper. Also check compatibility with cord stoppers: the cord with its cord end must pass through the stopper's hole during assembly.
Length and look
Length is not just a technical parameter. Long, thin cord ends look elegant on sweatshirts and fashion tops, while short, wide ones look sporty. With heavy metal cord ends, a greater length adds weight, which keeps the cord taut and hanging neatly. If the cord end will carry a logo, the length must accommodate the lettering or symbol without losing legibility.
Common sizing mistakes
- Measuring the cord under tension – this gives a smaller value than the real one.
- Choosing by the nominal cord size without taking end sealing into account.
- A cord end that does not pass through the eyelet when the cord is replaced.
- The same cord end size for cords with different braids in the collection.
- No sample with the actual cord before production.
How to specify the size in your inquiry
State the type of cord (round, flat, elastic), the material, the diameter or width measured with a calliper, the attachment type, the desired length and material of the cord end, the finish and whether there is a logo. Ideally, also send a sample of the cord. If you order the cord from us too, we will match the cord end to it. You will find more about cords in our cords category.
Sizing a set of cord, stopper and cord end
When a product has a cord, a stopper and a cord end, the sizes are chosen in a particular order. First comes the cord – its thickness depends on the channel and the desired look. Then the stopper, whose hole must accept the cord, and often two cords at once. Finally the cord end – with an inner diameter matching the cord and an outer diameter that allows the stopper to be threaded on during assembly or, conversely, stops the stopper from falling off. If the reverse order is chosen, it is easy to end up with a combination that cannot be assembled.
Cord ends in the exact size from Polkom
Polkom offers cord ends and aglets in various inner diameters, lengths and shapes, metal and plastic, as well as custom production. Send a sample of your cord and a description of the product via our contact page – we will suggest the right size and a sample for testing.
