Enamelled Wire

Not sure which kind of magnet wire you need? Then you've come to the right place. Call TEMCo at 877.474.8209 or view our online product selection by clicking the links below.

View our enamelled wire selection here:

Soderon 155 » GP/MR-200 »


What is Enamelled Wire?

Enamelled wire has a very thin layer of insulation or enamel. The wire is typically copper or aluminum, while the insulation is either a thin varnish or a polyester or fiberglass yarn.


Enamelled wire is used in applications which require tight coils of wire, in applications such as inductors, motors, speakers, hard disk head actuators, or electromagnets.

Most enamelled wire will be copper, but aluminum is also used in certain applications, such as large transformers and loudspeaker coils.

There are numerous reasons that copper is the most widely used metal in enamelled wire.

Copper is the highest electrical conductivity of all non-precious metals. Because it has a lower conductivity than copper, aluminum wire requires a cross section that is 1.6 times larger for it to create the same current capability as a copper wire, making copper wire more energy efficient aluminum wire.

Copper is also 300% stronger than aluminum, allowing it to withstand more extreme conditions.

Enamelled Wire for Motor Enamelled Wire for Speaker Enamelled Wire for Transformer

Enamelled Wire Specifications

Conductor Type

Most enamelled wire will be copper, but aluminum is also used in certain applications, such as large transformers and loudspeaker coils.

Aluminum has a lower conductivity than copper, so aluminum wire requires a cross section that is 1.6 times larger for it to create the same resistance as a copper wire. This makes copper wire more energy efficient and less cumbersome, than aluminum wire.


Common shapes for enamelled wire are square, round or rectangular.

The shape of the wire will determine how tightly the wire can be coiled. Square copper wires, for example, will be wound tighter since they have less space between the turns when they are formed in a coil. For this reason, they are often used in confined spaces and in applications where higher power is required.

Rectangular copper wires can be wound even tighter. They are arranged in a plane and then laminated into a flat ribbon. Rectangular copper wire is used on edge-wound spring coils.

Round wire, on the other hand, will have more space between the wires and cannot be wound as tightly due to its shape.

There are also hexagonal wires available; they are used in voice coils.


The color of enamelled wire has no bearing on the wire itself. It is purely aesthetic, and neither the insulation, nor any other element of how the wire will function, will be impacted. Wires can come in a variety of colors, including red, green and amber.

In cases where a certain wire color is preferred, some manufacturers will provide customers with a wire in that specific color.

Color enamelled Wire


Insulation serves to enhance the thermal endurance of the wire and is used to protect the wire from shorting out by coming in contact with itself. Insulation is especially important for coils that requires hundreds, possibly thousands, of wire turns.

Square or rectangular wires that have insulations that are thicker than average can sometimes come with an additional high-temperature polyimide or fiberglass tape. The strength and long-term reliability of the winded wire are improved by an extra insulating varnish.

Different insulation types will have different thermal capacity, diameter (which can be measured in millimeters or inches), AWG wire size and application.

Polyester and polyurethane are popular insulations, but there are many different types of insulation to chose from, including:

  • Polyester-imide has high thermal endurance and solvent resistance. It also has good windability due to a low friction.
  • Polyamideimide is designed to be used in inverter duty applications and motors that may experience voltage spikes.
  • Formvar: is very flexiable and has high resistance to abrasion.
  • Polyester Nylon is a dual coat insulation, with a polyester basecoat and a nylon topcoat. The polyester has high thermal properties and the nylon provides high mechanical properties.
  • Polyester-amide-imide is a dual coat insulation, which has a polyester basecoat and an amide-imide outer coating. This insulation provides the wire with increased windability, heat shock resistance and increased overload capacity. Polyester-amide-imide also has an increased chemical resistance to most solvents and insulating varnishes.
  • Dacron glass a served filament that is available either unvarnished or varnished with silicon or organic material. Dacron glass is a combination of glass and polyester fibers. It has improved flexibility and is abrasion resistant.
  • Polyamide-ML is made of polyimide resins. Good resistance to chemical solvents and burnout. Typically used in extreme conditions given its high ability to withstand overload and ability to not be affected by exposure to varnish solvents.

Older insulation materials used to be made of things like cotton, paper, or silk. These are only useful for low-temperature applications with a thermal rating of 105°C.

Large power transformers that operate at high voltages may be insulated by oil-impregnated paper or pressboard, examples of electrical insulation paper.

The wires offered by TEMCo come with a polyurethane insulation that is overcoated with polyamide. It will have a thermal rating of 155°C. TEMCo also offers wires with a polyester-imide insulation that comes overcoated with polyamide-imide. This wire has a thermal rating of 200°C.

Wire Gauge

The American wire gauge (AWG) rating of the wire, used in the U.S. and Canada, represents specific characteristics of round wire, such as diameter, resistance and current.

As the wire diameter decreases, the AWG number will increase. For instance, wire with a diameter of 5.827 millimeters will have an AWG size of 3, while a wire with a diameter that measures 0.101 millimeters will have an AWG size of 38.

There are 44 standard wire gauges in total, that range from 0000 to 40. The 0000 gauge wire will have a diameter of 11.684 mm, while the 40 gauge wire has a diameter of 0.0799 mm.

Enamelled Wire Gauge


Wire weight will also be based on AWG standards and will have an inverse relationship with the gauge, meaning as the gauge becomes greater, the weight of the wire will decrease.

The 0000 gauge wire will have a weight of 640.5005 lbs per 1000 feet, while the 40 gauge wire has a weight is 0.0299 lbs per 1000 feet.

Temperature Rating/Thermal Class

The temperature of the wire at which it will have a 20,000 hour service life is called the thermal class, or temperature rating. The service life of the wire can be extended by using the wire at a lower temperature.

Thermal class is measured in degrees celsius. 130°, 155°, 180° and 200° are some common temperatures found in different types of insulation. The maximum thermal class is 250°.

Bondable Enamelled Wire

Wire that contains an extra adhesive film, which can be epoxy, polyester or polyamide, on top of the usual insulation that activates when heated up is called bondable wire. The turn to turn windings of the wire will bond into a coil that is self-supporting, eliminating the need for the spindles around which the wire is wound, called bobbins.

There are three main types of bonding: solvent, oven and resistance.

A solvent bonding coat will be applied while the wire is winding, or else the completed coil will be dipped in a solvent once the winding has completed.

During oven bonding, the wire is fully wound and then put into an oven. Depending on the size of the coiled wire, oven bonding time can range from 10 to 30 minutes.

Resistance bonding uses an electric current to bond the completed windings. The size of the wire and the design of the coil will determine how long it will take to complete the process. Resistance bonding is used for wire sizes 34 gauge or higher.

Soldering Process

The enamelled wire will eventually need to be soldered, which is the process in which two metals are fused together by a third metal. The third metal will be melted down and then resolidify to join the other two metals together.

Older wire might require the insulation to be removed first before the wire can be soldered, but the majority of wire being made now will not require its enamel to be removed before being soldered, as the insulation will act as a flux when burnt.

Breakdown Voltage

The dielectric strength of the enamel insulation of the wire is also known as the breakdown voltage.

There are three types of breakdown voltage: Grade 1, Grade 2 and Grade 3. The breakdown voltage grade will increase with thicker insulations. Breakdown voltage is based on AWG standards, with smaller gauges having higher breakdown voltages.

The insulation thickness, or build, is the measurement of the enamel, which can be calculated by subtracting the total diameter of the wire from the total diameter of the insulation and wire together.

Insulation build can be single, heavy, triple or quadruple. Single and heavy are the most common.

Where can I buy Enamelled Wire?

View the enamelled wire selection from TEMCo by clicking the links below. We have wires in numerous different gauges, temperature ratings and insulations. Find your enamelled wire at TEMCo today!

View Soderon 155 Wire Selection View GP/MR-200 Wire Selection

Call us at 877.474.8209