Abstract: To address quality issues such as conductor strand jumping, resistance fluctuation, and insulation eccentricity in the production of dual-core copper conductor overhead insulated wires, key process optimizations were implemented across wire drawing, stranding, and insulation extrusion. In the drawing process, the online annealing system was activated to control the tensile strength of copper wires at 405~450 N·mm⁻², with wire diameter adjusted to 1.33~1.34 mm, resolving strand jumping caused by excessive hardness. For the stranding process, the first-stage die was redesigned into a 7-hole constrained structure, and angles between the wire separator and dies were matched, significantly reducing work hardening. In the insulation process, the die core sizing zone length was increased to 35 mm and the center distance adjusted to 6.6 mm, effectively eliminating insulation eccentricity and substandard minimum thickness points. Post-optimization trial production showed: conductor tensile breaking force reached 3.807 kN, DC resistance at 20 ℃ decreased to 1.887 Ω·km⁻¹, and insulation minimum thickness improved to 0.86 mm. All dimensional and appearance criteria were met. This optimized approach provides a reliable technical reference for producing multi-core copper conductor overhead insulated cables.