Magnetic Wire

Part Number	Description / PDF	Quantity
30HNSP.125 Remington Industries	MAGNET WIRE, HEAVY BUILD ENAMELE	28
40SNS5 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	48
32H2002.5 Remington Industries	MAGNET WIRE, 200C, 32 AWG, 2.5 L	49
42SNS2.5 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	50
18H200 Remington Industries	18H200 MAGNET WIRE, ENAMELED COP	47
18SNSP Remington Industries	18SNSP MAGNET WIRE, ENAMELED COP	92
22H2002.5 Remington Industries	MAGNET WIRE, 200C, 22 AWG, 2.5 L	50
21SNSP.5 Remington Industries	21SNSP.5 MAGNET WIRE, ENAMELED C	49
35SNSP.25 Remington Industries	35SNSP.25 35 AWG MAGNET WIRE, EN	47
26HNSP.125 Remington Industries	MAGNET WIRE, HEAVY BUILD ENAMELE	42
3522 Adafruit	ENAMELED COPPER MAGNET WIRE 11	1
610224 CnC Tech	MW-28C SL 24AWG 1KG MAX/V 1900	21
8073 Belden	MW-35C HY 14AWG	66134
43SNSP.5 Remington Industries	43SNSP.5 43 AWG MAGNET WIRE, ENA	50
600218 CnC Tech	MW35-C HY 18AWG 1KG MAX/V 3900	114
26H200 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	48
36SNSP.5 Remington Industries	36SNSP.5 MAGNET WIRE, ENAMELED C	47
610230 CnC Tech	MW-28C SL 30AWG 1KG MAX/V 1700	27
29SNSP.5 Remington Industries	29SNSP.5 29 AWG MAGNET WIRE, ENA	50
600222 CnC Tech	MW35-C HY 22AWG 1KG MAX/V 3600	52

Magnetic Wire

1. Overview

Magnetic wire, also known as winding wire, is a critical component in electromagnetic devices such as transformers and inductors. It consists of a conductive core (typically copper or aluminum) insulated by a thin polymer coating. Its primary function is to convert electrical energy into magnetic energy and vice versa, enabling voltage transformation, current regulation, and energy storage. With the rapid development of power electronics, renewable energy systems, and electric vehicles, magnetic wire has become indispensable in modern electrical and electronic systems.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Enameled Wire	Thin enamel insulation, high thermal conductivity, excellent dielectric strength	High-frequency transformers, motors, inductors
Film-insulated Wire	Polyester or polyimide film wrapping, enhanced mechanical protection	High-reliability aerospace systems, medical devices
Silk-wrapped Wire	Natural silk fiber insulation, flexible for manual winding	Vintage audio equipment, specialized audio transformers
Self-bonding Wire	Adhesive coating enables coil self-support without bobbins	Compact inductors, wireless charging coils

3. Structure and Composition

A typical magnetic wire comprises three key layers:

Conductive Core: Oxygen-free copper (OFC) or aluminum for optimal conductivity
Primary Insulation: Thermosetting polymer enamel (e.g., polyurethane, polyester-imide)
Surface Coating: Optional adhesive or lubricant layer for winding process optimization

The cross-sectional diameter ranges from 0.02mm (magnet wire in micro-inductors) to 5.0mm (heavy-duty transformer windings).

4. Key Technical Specifications

Parameter	Description	Importance
Wire Gauge (AWG/mm )	Defines current-carrying capacity and resistance	Determines thermal performance and voltage drop
Temperature Class	Thermal endurance rating (130 C to 220 C)	Dictates operational lifespan in high-temperature environments
Dielectric Strength	Voltage withstand capability (kV/mm)	Ensures electrical safety and insulation reliability
Thermal Index	Resistance to thermal aging	Impacts long-term stability in power electronics

5. Application Fields

Power Industry: Grid transformers, HVDC converters
Electronics: Switch-mode power supplies (SMPS), EMI filters
Automotive: EV motor windings, onboard chargers
Renewables: Solar inverters, wind turbine generators

Case Study: In electric vehicles, 400V-class magnetic wires with Class 180 thermal rating enable compact traction motor designs achieving >95% efficiency.

6. Leading Manufacturers and Products

Manufacturer	Headquarters	Representative Product
Essex Furukawa	USA	ECW-180 (High-temperature enameled wire)
Leoni AG	Germany	AIWIRE (Automotive isolation wire)
Sumitomo Electric	Japan	PEEK-insulated wire for hybrid vehicles

7. Selection Guidelines

Calculate current density (typically 3-5A/mm for standard applications)
Select temperature class based on ambient conditions (+25 C derating per 10 C above rating)
Evaluate dielectric requirements per IEC 60317 standards
Consider cost/performance trade-offs: Copper (higher conductivity) vs. Aluminum (lightweight, lower cost)

8. Industry Trends

Miniaturization: Development of 0.01mm-diameter wires for 5G RF inductors
High-Temperature Materials: Polyamide-imide (PAI) enamel enabling 220 C operation
Sustainability: Bio-based insulation coatings reducing VOC emissions
Integrated Solutions: Embedded magnetic wires in PCB substrates for EV chargers

Market forecasts predict 6.2% CAGR through 2030 driven by renewable energy integration and electrified transportation demands.