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Magnet and Specialty Wire

Flat Magnet Wire, Round Magnet Wire, Specialty Wire

Bridgeport Magnetics' "Flat Magnet Wire" was introduced in 2001 and has gained wide acceptance among manufacturers of power supplies and specialty motors in many countries. The original product covered wire sizes 0.55 to 1.4mm in the round (25 to 16 AWG) shaped with thickness to width ratios of 1:2, 1:3, and 1:4.

For higher ratios than 1:4 (thinner compared to the width) check our LAMINAX products!

Extended size range, 32 to 11AWG , now also offered as round wire.

Bridgeport Magnetics'  "Flat Wire" program has been extended downwards to 0.24mm diameter (32 AWG) and upwards to 2.39 mm (12 AWG). All sizes will be available on spools measuring 6"OD x3.5" (10 lb.

The Flex System 

Along with extending the range of wire sizes we are now offering added flexibility allowing users to select the required cross sectional area in sq.mm or sq.mils, or in terms of wire resistance, ohms/1000 Ft. or ohms/Kilometer as well as either the desired target width or thickness. With this information we will calculate the closest second dimension possible inside our max. 1:4 thickness/width range, and will be able to ship orders of 10 lbs. and over made to measure, usually within one to two days.

Of course customers will still be able to specify AWG sizes and flattening ratios of 1:2, 1:2.5, 1:3, 1:3.5 and 1:4 according to our tables. The FLEX SYSTEM however, is an option offered at no added cost, which will sometimes enable the user to optimize a design even further than possible with the fixed ratios.

The Process 
 
The pre-insulated wire or bare wire is flattened utilizing proprietary equipment in a single step deformation between mirror polished work surfaces. It is special for the process that the deformation is performed with  negligible elongation meaning that the cross sectional area is reduced only marginally. The result is that even at the maximum ratio of deformation 1:4, the insulation is stretched no more than 25% on the flats, and in one direction only (crosswise).

Years of experience has shown that the flattening preserves the integrity of practically all types of insulation including solderable polyurethanes and bond-coats as well as high temperature polymide/imide coatings. Studies of sections of flattened wire show a continuous rather than an angular transition from the flats into semi elliptical edges practically without any stress concentrations. The product also does not exhibit the "dogbone" shape often encountered in post insulated rectangular wire due to surface tension drawing the varnish away from the wire edges.

Work Hardening
 
Depending on the flattening ratio the process normally involves a degree of work hardening, which leaves the wire somewhat harder than post insulated wire. The increased stiffness is perceived as an advantage in certain applications.

Inches Standard Ratios
Click on AWG to Purchase

Flat Wire
AWG Size

Ratios- Inches (All dimensions over insulation)

1:2

1:2.5

1:3

1:3.5

1:4

Flat Wire
AWG 
Dia T W T W T W T W T W
in in in in in in in in in in in
11 0.094 0.059 0.118                
11.5 0.089 0.056 0.112                
12 0.084 0.053 0.105                
12.5 0.080 0.050 0.100                
13 0.075 0.047 0.094 0.042 0.106            
13.5 0.071 0.045 0.089 0.040 0.100            
14 0.068 0.042 0.085 0.038 0.095 0.035 0.104        
14.5 0.064 0.040 0.080 0.036 0.089 0.033 0.098        
15 0.060 0.038 0.076 0.034 0.084 0.031 0.093        
15.5 0.057 0.036 0.072 0.032 0.080 0.029 0.088        
16 0.054 0.034 0.067 0.030 0.075 0.028 0.083 0.025 0.089 0.024 0.095
16.5 0.051 0.032 0.064 0.029 0.071 0.026 0.078 0.024 0.085 0.023 0.090
17 0.048 0.030 0.060 0.027 0.068 0.025 0.074 0.023 0.080 0.021 0.085
17.5 0.046 0.029 0.057 0.026 0.064 0.023 0.070 0.022 0.076 0.020 0.081
18 0.043 0.027 0.054 0.024 0.060 0.022 0.066 0.020 0.071 0.019 0.076
18.5 0.041 0.026 0.051 0.023 0.057 0.021 0.062 0.019 0.067 0.018 0.072
19 0.039 0.024 0.048 0.022 0.054 0.020 0.059 0.018 0.064 0.017 0.068
19.5 0.037 0.023 0.046 0.021 0.051 0.019 0.056 0.017 0.061 0.016 0.065
20 0.035 0.022 0.043 0.019 0.048 0.018 0.053 0.016 0.057 0.015 0.061
20.5 0.033 0.020 0.041 0.018 0.046 0.017 0.050 0.015 0.054 0.014 0.058
21 0.031 0.019 0.039 0.017 0.043 0.016 0.048 0.015 0.051 0.014 0.055
21.5 0.029 0.018 0.037 0.016 0.041 0.015 0.045 0.014 0.049 0.013 0.052
22 0.028 0.017 0.035 0.015 0.039 0.014 0.042 0.013 0.046 0.012 0.049
22.5 0.027 0.017 0.033 0.015 0.037 0.014 0.041 0.013 0.044 0.012 0.047
23 0.025 0.016 0.031 0.014 0.035 0.013 0.038 0.012 0.041 0.011 0.044
23.5 0.024 0.015 0.029 0.013 0.033 0.012 0.036 0.011 0.039 0.010 0.042
24 0.022 0.014 0.028 0.012 0.031 0.011 0.034 0.011 0.037 0.010 0.040
24.5 0.021 0.013 0.026 0.012 0.030 0.011 0.032 0.010 0.035 0.009 0.037
25 0.020 0.012 0.025 0.011 0.028 0.010 0.031 0.009 0.033 0.009 0.035
25.5 0.019 0.012 0.024 0.011 0.026 0.010 0.029 0.009 0.031 0.008 0.033
26 0.018 0.011 0.022 0.010 0.025 0.009 0.027 0.008 0.030 0.008 0.032
26.5 0.017 0.011 0.021 0.010 0.024 0.009 0.026 0.008 0.028 0.008 0.030
27 0.016 0.010 0.020 0.009 0.023 0.008 0.025 0.008 0.027 0.007 0.029
27.5 0.015 0.010 0.019 0.009 0.021 0.008 0.023 0.007 0.025 0.007 0.027
28 0.014 0.009 0.018 0.008 0.020 0.007 0.022 0.007 0.024 0.006 0.026
28.5 0.014 0.009 0.017 0.008 0.019 0.007 0.021 0.006 0.023 0.006 0.024
29 0.013 0.008 0.016 0.007 0.018 0.007 0.020 0.006 0.022 0.006 0.023
29.5 0.012 0.008 0.015 0.007 0.017 0.006 0.019 0.006 0.020 0.005 0.022
30 0.012 0.007 0.015 0.007 0.016 0.006 0.018 0.005 0.019 0.005 0.021
30.5 0.011 0.007 0.014 0.006 0.016 0.006 0.017 0.005 0.018 0.005 0.02
31 0.01 0.007 0.013 0.006 0.015 0.005 0.016 0.005 0.017 0.005 0.019
31.5 0.01 0.006 0.013 0.006 0.014 0.005 0.015 0.005 0.017 0.004 0.018
32 0.009 0.006 0.012 0.005 0.013 0.005 0.015 0.004 0.016 0.004 0.017

 

Metric Standard Ratios
Flat Wire
AWG Size
Ratios- Millimeter (All dimensions over insulation)
1:2 1:2.5 1:3 1:3.5 1:4
AWG  Dia T W T W T W T W T W
mm mm mm mm mm mm mm mm mm mm mm
11 2.39 1.50 3.00                
11.5 2.26 1.42 2.83                
12 2.14 1.34 2.68                
12.5 2.02 1.27 2.53                
13 1.92 1.20 2.40 1.07 2.68            
13.5 1.81 1.13 2.27 1.01 2.54            
14 1.71 1.07 2.15 0.96 2.40 0.88 2.63        
14.5 1.62 1.02 2.03 0.91 2.27 0.83 2.49        
15 1.53 0.96 1.92 0.86 2.15 0.78 2.35        
15.5 1.45 0.91 1.82 0.81 2.03 0.74 2.23        
16 1.37 0.86 1.71 0.77 1.91 0.70 2.10 0.65 2.27 0.61 2.42
16.5 1.30 0.81 1.62 0.73 1.82 0.66 1.99 0.61 2.15 0.57 2.30
17 1.22 0.77 1.53 0.69 1.72 0.63 1.88 0.58 2.03 0.54 2.17
17.5 1.16 0.73 1.45 0.65 1.62 0.59 1.78 0.55 1.92 0.51 2.05
18 1.09 0.69 1.37 0.61 1.53 0.56 1.68 0.52 1.81 0.49 1.94
18.5 1.03 0.65 1.30 0.58 1.45 0.53 1.59 0.49 1.71 0.46 1.83
19 0.98 0.61 1.23 0.55 1.37 0.50 1.50 0.46 1.62 0.43 1.73
19.5 0.93 0.58 1.17 0.52 1.30 0.48 1.43 0.44 1.54 0.41 1.65
20 0.88 0.55 1.10 0.49 1.23 0.45 1.35 0.42 1.46 0.39 1.56
20.5 0.83 0.52 1.04 0.47 1.16 0.42 1.27 0.39 1.38 0.37 1.47
21 0.79 0.49 0.99 0.44 1.10 0.40 1.21 0.37 1.31 0.35 1.40
21.5 0.74 0.47 0.93 0.42 1.04 0.38 1.14 0.35 1.23 0.33 1.32
22 0.70 0.44 0.88 0.39 0.98 0.36 1.08 0.33 1.16 0.31 1.24
22.5 0.68 0.42 0.85 0.38 0.95 0.35 1.04 0.32 1.12 0.30 1.20
23 0.63 0.40 0.79 0.35 0.89 0.32 0.97 0.30 1.05 0.28 1.12
23.5 0.60 0.37 0.75 0.33 0.84 0.31 0.92 0.28 0.99 0.26 1.06
24 0.57 0.35 0.71 0.32 0.79 0.29 0.87 0.27 0.94 0.25 1.00
24.5 0.54 0.34 0.67 0.30 0.75 0.27 0.82 0.25 0.89 0.24 0.95
25 0.51 0.32 0.63 0.28 0.71 0.26 0.78 0.24 0.84 0.22 0.90
25.5 0.48 0.30 0.60 0.27 0.67 0.25 0.74 0.23 0.80 0.21 0.85
26 0.45 0.28 0.57 0.25 0.63 0.23 0.69 0.21 0.75 0.20 0.80
26.5 0.43 0.27 0.54 0.24 0.61 0.22 0.66 0.20 0.72 0.19 0.77
27 0.41 0.26 0.51 0.23 0.57 0.21 0.63 0.19 0.68 0.18 0.72
27.5 0.39 0.24 0.49 0.22 0.54 0.20 0.60 0.18 0.64 0.17 0.69
28 0.37 0.23 0.46 0.20 0.51 0.19 0.56 0.17 0.61 0.16 0.65
28.5 0.35 0.22 0.44 0.20 0.49 0.18 0.53 0.16 0.58 0.15 0.62
29 0.33 0.21 0.41 0.19 0.46 0.17 0.51 0.16 0.55 0.15 0.59
29.5 0.31 0.20 0.39 0.18 0.44 0.16 0.48 0.15 0.52 0.14 0.55
30 0.29 0.18 0.37 0.17 0.41 0.15 0.45 0.14 0.49 0.13 0.52
30.5

0.28

0.177

0.353

0.158

0.395

0.144

0.432

0.133

0.467

0.125

0.499

31 0.27 0.166 0.333 0.149 0.372 0.136 0.407 0.126 0.440 0.118 0.470
31.5 0.25 0.159 0.318 0.142 0.356 0.130 0.390 0.120 0.421 0.113 0.450
32 0.24 0.150 0.301 0.135 0.336 0.123 0.368 0.114 0.398 0.106 0.425