<p>This work explores the Oldroyd 8-constant fluid flow model accompanied by the thermal radiation in a pore environment on wire coating analysis. Varying viscosity and thermal conductivity are taken for investigating a steady electrically conducting flow with magnetic force and energy generation. The die coating is under a porous environment. Current fluid phenomena are modeled, and a comparison of Reynolds and Vogel’s variable viscosity models is studied. Novelty is comparative study incorporating variable viscosity, variable thermal conductivity, Brinkman number, and radiation simultaneously in wire coating. Therefore, the governing equations for the current model are changed to differential equations that are not linear with dimensionless variables. These mathematical equations are numerically solved by transformation to nonlinear ODE’s solved numerically using BVP4C. The impact of various characteristics affecting velocity and temperature distributions is depicted graphically, including the dilatant constant, the magnetic field parameter, the porosity parameter, the pseudoplastic constant, variable thermal conductivity parameter, Brinkman number, and thermal radiation parameter. The results indicate that, in both Reynolds model and Vogel’s model, the thermal field shows opposite trends as the thermal radiation parameter grows. Nusselt number increases in the Reynolds model for enhanced values of thermal radiation. This study finds a crucial role in ensuring the performance, reliability, and safety of wires and cables in various industries such as automotive, aerospace, electronics, telecommunications, and power distribution.</p>