The Benefits of Flat Wire

Flat wire, is a unique type of wire with a rectangular cross-section. This distinctive shape offers several advantages over traditional round wire, making it a versatile choice for various industries and applications.

Flat wire is typically made from materials such as copper, aluminum, or stainless steel. Its flat, wide profile allows it to fit into small spaces and be easily manipulated to suit different shapes and designs. This unique geometry provides consistent electrical qualities, including impedance, capacitance, and inductance.

Common Aloys of Flat Wire

Flat gold and silver wires are used in various industries due to their high conductivity, corrosion resistance, and biomedical compatibility. Gold and silver flat wires are used in electrical components where high speed transmissions are needed.

MWS has been producing for years. Here are some alloys that can be made into flat wire.

• Precious metals wire (including Gold and silver)
• Copper and copper alloy wire
• Plated wire (including gold, nickel, silver, and tin plating)

Flat wire is frequently used as a heating element in both domestic and industrial applications for hot wire cutting, sealing, and other heat treatments. Chromium based flat wires have high resistivity and high mechanical strength operating at temperatures up to 2192°F.

Resistance wire and chromium based alloys

Applications of Flat Wire

Flat wire finds use in various industries:

• Electronics: Used in transformers, inductors, and other components where heat dissipation and efficient power flow are crucial.
• Automotive: Employed in electrical systems, offering both flexibility and durability.
• Medical Devices: Used in percutaneous catheters, neurovascular devices, and self-expanding stents, where precision and reliability are essential.
• Construction: Serves as a crucial component in reinforcing structures and connecting various elements.
• Aerospace: Utilized in applications where weight and space considerations are paramount.

Flat Wire Manufacturing

MWS produces flat rolled wire by taking round wire and passing through one of our two rolling mills. Size ranges from .0005” thickness and widths up to .125”. Most alloys including copper and aluminum are available as rolled wire. High width to thickness ratios can also be insulated with custom dimensions and bond coats.

The MWS Advantage

MWS offers custom spooling options to ensure flat wire is stored correctly and preforms as intended.  The spooling of wire matters as much as the mechanical properties of the wire itself. MWS employs several techniques such as layer winding to facilitate proper function during storage and de-spooling.