This study focusses on the wire coating process to insulate conducting wires with molten polymers for mechanical strength and defense in harsh conditions. The third-grade fluid model is satisfied in the current study on wire coating, which is carried by utilizing radiative melt polymer. This study is new as it examines how wire coating is affected by porosity, thermal radiation parameter, and variable temperature dependent viscosity. The Reynolds Model and Vogel’s Model have considered temperature-dependent viscosity. The non-linear differential equations are resolved regular perturbation approaches as well as by fourth order R-K method. Heat transfer phenomena, and graphs are used to illustrate the impacts of the relevant parameters. It is noteworthy that while the results previously provided show that a rise in non-Newtonian parameters improves velocity in the absence of porous matrix, this effect is reversed in the presence of porous matrix. It is also interesting to note that in the presence of a porous matrix, the process is accelerated by an increase in the heat radiation parameter. Furthermore, Vogel’s model clearly illustrates the flow instability in the flows of the extrusion die.