Substructure strengthening has been utilized by the wire industry to produce high strength, high conductivity, ductile aluminum wire suitable for electrical usage. This paper describes the choice of alloy additions and production methods necessary for producing and stabilizing a small subgrain structure. The interrelation between the various manufacturing steps, such as casting, rolling, and drawing, and the resulting microstructure which controls the electrical and mechanical properties is discussed. The necessity for strict control of the processing parameters established for various aluminum wire products is emphasized.