Flat Magnet Wire


Flat Magnet Wire is produced from round pre-insulated magnet wire that is flattened between mirror polished work surfaces. Insulation is stressed in only one direction, and resistance and wire gauge remain largely unchanged. Wire comes in 10 or 20 lb spools and 5 ratios of thickness to width. User can select cross sectional area in sq mm or sq mil, or in terms of wire resistance. Insulation is Polyester/Polyamideimide or Polyester/Polyamideimide/Bondcoat.

Flat magnet wire is useful in products such as voice coils in loudspeakers, field and armature coils in rotary and linear motors, and transformers, in which the flat wire permits more compact coils and improved heat dissipation, as compared to designs based on round wire.

Flat wire is available with two types of insulation:



180°C Bondable


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We offer AWG 11 – AWG 32 with Ratios of 1:2, 1:2.5, 1:3, 1:3.5, 1:4, but we can sometimes optimize a design even further than possible with the fixed ratios.



The wire that is already insulated or bare wire is flattened by making use of proprietary gear in a solitary process of deformation between mirror refined work surfaces. It is critical for the deformation process that it is performed with insignificant elongation. This means that the cross sectional area is reduced only slightly. The consequence is that even at the highest ratio of deformation, which is 1:4, the insulation is extended no more than 25% on the flat wire, and also in one direction only (crosswise).


Flattening conserves the reliability of virtually all types of insulation including high temperature polymide/imide coatings and bond-coats as well as solderable polyurethanes(MW16, MW35, MW79, MW80). Studies of sections of flattened wire show unbroken rather than a pointed conversion from the flats into semi elliptical edges, and do it with basically no stress concentrations. The flat wire also does not display the “dogbone” profile often shown in post insulated rectangular wire. This is due to surface tension deriving the varnish away from the wire edges.


No. 1 Edge A Smooth, uniform, round or square edge, either slit or filed or slit and edge rolled as specified, width tolerance +- .005".
No. 2 Edge A natural round mill edge carried through from the hot rolled band. Has not been slit, filed, or edge rolled. Tolerances not closer than hot-rolled strip limits.
No. 3 Edge Square, produced by slitting only. Not Filed. Width tolerances close.
No. 4 Edge A round edge produced by edge rolling either from a natural mill edge or from slit edge strip. Not as perfect as No. 1 Edge. Width tolerances liberal.
No. 5 Edge An approximately square edge produced by slitting and filing or slitting and rolling to remove burr.
No. 6 Edge A square edge produced by square edge rolling, generally from square edge hot-rolled occasionally from slit strip. Width tolerances and finish not as exacting as No. 1 Edge.




Depending on what ratio the customer selected, the procedure usually engages an extent of work hardening. This leaves the wire fairly harder than post insulated wire. The amplified rigidity is perceived as a benefit in some applications.