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MAGNET WIRE

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magnet wire - enameled flat wire with CTC wire

About magnet WIRE

Copper flat wire is a rectangular or square cross-section copper conductor, produced by rolling or drawing Ø8–12.5mm copper rod through a sequence of forming rolls and dies. Unlike round wire, which is primarily used for cable and winding applications, flat wire offers higher surface area-to-volume ratio and improved heat dissipation, making it ideal for high-frequency and high-power applications.
• Raw Material Sources
– Produced from Ø8–12.5mm copper rod via Rolling (+ Drawing) processes (including Konform TLJ300/300H)
• Available Sizes
– Thickness: 0.8 – 4.5 mm (depending on final application)
– Width: 2.0 – 20.0 mm
– Cross-sectional area: 2 –90 mm²
• Processing Routes & End Products
The production of copper flat wire follows a well-established processing sequence. The starting material, Ø8–12.5mm copper rod, is first processed through rolling mills or drawing benches to achieve the desired rectangular or square cross-section. The formed flat wire can then be further processed in four key routes:

– Bare Flat Wire: Used directly in busbar connections, transformer windings, and electrical connectors

– Enameled Flat Wire (Magnet Wire): Coated with insulating enamel via enameling machines for motor and transformer windings requiring high thermal ratings

– Paper Wrapped Flat Wire: Wrapped with paper insulation via lapping machines for oil-immersed transformer applications

– CTC Wire (Continuously Transposed Conductor): Transposed and combined with other flat wires to form CTC for high-voltage transformer windings

Through these integrated processing routes, copper flat wire serves as a critical material for the electrical equipment manufacturing industry, delivering reliable conductivity, thermal performance, and mechanical strength across a wide range of applications, including transformer windings, motor coils, generators, reactors, and specialty electrical components.

Flat Wire Rolling Mill

Flat Wire Rolling Mill

Flat wire rolling mill

Flat Wire Rolling Machine

Flat wire rolling mill

Continuous Extrusion Machine

copper continuous extrusion machine

Continuous extrusion machine

Take-up of continuous extrusion machine

Enameling Machine

Horizontal Enameling Machine

High-spped horizontal enameling line

enameling

Pay-off of high-speed horizontal enameling line

CTC (Continuously Transposed Conductor) Line

CTC line

India-CTC-Wire-Plant

CTC line

Paper Wrapping / Lapping Machine

Paper lapping machines

Papper wrapping plant

Take-up of papper wrapping machines