Magnet wire is made from copper, aluminum or stainless steel and thinly insulated with enamel. Copper magnet wire is not magnetic itself in most cases, but it is used in magnetic applications for a variety of products, such as loudspeakers, electronic transformers, headphones and other electronic products.

When studying magnet wire information, you should know that the system used to measure gauge is American Wire Gauge, or AWG. The smaller the diameter of the wire, the larger the number.

Magnet wire pricing and costs depend on many factors, including the type of coating available. The right enamel varies depending on the application, but it can often add an additional cost of $5 to $15. Of course, type of metal the magnet wire is made from also affects price. Other options include:

1. The gauge of the magnet wire products.

2. The size of the wire spool.

3. Whether the wire is round or square.

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Choose large gauge stainless steel magnet wire for big items

If you have a large job that requires magnet wire, you'll need a large gauge to provide the correct amount of electricity between connections. Gauge sizes below 40 are typically used for large electrical items like generators, alternators, motors and certain types of power tools. Cost depends on the size of the spool and the specific gauge, but you can get 10 to 30 gauge magnet wire in a 7-pound spool for $50 to $70. Fourteen-pound spools are also available for $70 to $100.

I recommend: Surplus Sales of Nebraska sells a variety of large gauge magnet wire in full reels or cut to a particular length. Applied Magnets offers 7- and 11-pound spools for wire gauges 10 through 34.

Buy small gauge magnet wire

A small gauge magnet wire, AWG 40 or above, is often used for very small electrical systems, including headphones speakers and other electronic products. Smaller gauge wire is somewhat less expensive than larger gauge spools; a 5- to 9-pound spool costs between $20 and $40. You can also find spools that have more than 100,000 feet of wire which are priced by the foot, not per pound.

I recommend: PlanetEngineers.com sells a variety of small gauges for magnet wire. The company also offers a bulk discount per pound of wire purchased. Ocean State Electronics sells 40 gauge magnet wire, along with other smaller gauges.

Order square magnet wire for your electronic projects

Though many gauges of magnet wire are round, some are square. This is due to the fact that aluminum wire needs 1.6 times the cross section area as copper wire to achieve the same amount of electrical conductivity. Square magnet wire is flat with rounded edges, which makes for an efficient use of the winding space. Square magnet wire usually costs $1 to $2 per foot.

I recommend: MWS Wire Industries has tools to help you find the correct gauge and insulation type for the magnet wire you need. HM Wire International provides many types of aluminum magnet wire in square and rectangular shapes.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Because magnet wire is used for electromagnetics and other electrical applications, always check magnet wire info on the current capacity to choose the right amount of current for your project.

Magnet wire is typically copper or aluminum wire with enamel insulation for superior heat resistance that generates an electrical field in applications for the motor, automotive, transformer and generator industries. Specific uses for magnetic wire products include appliance motors, small transformers, automotive coils, watches, loudspeakers and headphones.

Available on biconical spools for use on high-speed winding machines, tapered spools to accommodate heavier wire sizes and traditional straight barrel spools, the electrical conductor is available in a range of materials, insulation styles and gauges. Gather the following magnet wire information to help with your company's buying decision:

1. Analyze your project requirements to determine the suitable type of magnet wire conductor material and American Wire Gauge (AWG) size.

2. Decide if your application requires a special configuration of copper magnet wire, such as Litz wire that uses multiple individually-coated strands to reduce power loss.

3. Assess future needs to determine the amount of magnet wire you’ll need and get price quotes based on such factors as specific gauge, enamel build and temperature class.

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Match the right type of magnet wire to your company's requirements

Since suppliers of magnet wire offer versions with conductor materials such as copper, copper clad aluminum, brass, gold and stainless steel, insulation like Polyurethane or Polyester and thermal classes up to 220 degrees Celsius, it's essential to match the wire's properties to your application for maximum efficiency. The magnet wire info provided on manufacturer and distributor websites will reveal the ideal applications based on factors such as tensile strength, density and conductivity.

I recommend: Click on the types of conductor materials on the Elektrisola website to discover their properties and potential uses and then download the tool to compare resistance by diameter. Use the handy chart at PowerStream Technology to determine the load carrying capacities for each copper magnet wire AWG size and utilize the voltage drop calculator to determine your needs.

Determine if you need magnet wire with a multiple-strand configuration for high efficiency

By twisting or braiding separately insulated magnet wires, Litz wire allows each strand to take multiple positions along the cable to distribute the electrical current evenly and reduce power loss. The specialty wire is ideal for applications such as televisions, motors, relays, communications and sonar equipment.

I recommend: Once you’ve determined the AWG size your application requires, request Litz wire product information from Cooner Wire. Download free software from WireTronic that provides specifications and a resistance and break strength calculator.

Contact magnet wire suppliers to obtain quotes and ensure you get the best price

Although magnet wire prices vary according to such factors as the insulation, overcoat and thermal class, comparison shop and inquire about bulk magnet wire pricing if you plan to order multiple spools. Note that some distributors won't take returns on magnet wire unless you purchase a full spool.

I recommend: Request a price quote from HM Wire International for stainless steel magnet wire, as well as traditional, square and ultra fine versions. MWS Wire Industries offers quotes for round, square and bondable magnet wire. Both companies also sell and provide prices for Litz wire. Get a quote and information for high temperature magnet wire from Ceramawire.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Study the literature that comes with your specific wire type to determine proper storage methods for surplus magnet wire. For example, prevent moisture absorption by storing high temperature magnet wire with a desiccant in an airtight container.

Magnet wire is an important aspect in the generation of electricity. Magnet wire is "insulated electrical conductor, usually copper or aluminum, that when wound into a coil and energized creates a useful electrical field." There is more than one magnet wire type and style: copper magnet wire, stainless steel magnet wire, and square wire.

Below, you will find magnet wire information that will describe the various magnet types and styles, as well as information about magnet wire providers of magnet wire products. This should help your company when it comes to buying magnet wire.

1. Learn about copper magnet wire.

2. Understand stainless steel magnet wire.

3. Know about square magnet wire.

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Understand copper magnet wire

Copper magnet wire is probably the most prevalent magnet wire. The reason why copper is prized as magnet wire is due to the fact that copper is such a good conductor of electricity, second only to silver. Another reason is its cost, which is less than that of silver. Copper magnet wire can be various thicknesses as well as insulated or bare. Copper wire can also be high-temperature magnet wire.

I recommend: Quality Coils has various sizes of insulated copper magnet wire as well as high-temperature magnet wire. MWS Wire also has copper magnet wire that is either insulated or bare.

Learn about stainless steel magnet wire

Stainless steel magnet wire can also be insulated and be of various thicknesses. It is also possible to request that the wire be color coded according to your specifications. Like copper magnet wire, stainless steel magnet wire can also be high-temperature magnet wire.

I recommend: Wiretronic is a good source of stainless steel magnet wire (as well as other magnet wire types and styles). H M Wire is another source for stainless steel magnet wire.

Learn about square magnet wire

Square magnet wire is for motor windings as well as specialty coils. According to MWS Industries, the benefits of square magnet wire are that it 'allows design engineers to create compact coils and small motors that deliver more power in less space.' This wire can also be insulated or bare and come in various sizes.

I recommend: Alconex Specialty Products and Swiger Coil are good sources of square magnet wire.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  When ordering, ask the suppliers of magnet wire about bulk pricing, as well as asking them for more magnet wire info. Magnet wire suppliers would be more than willing to answer any questions you might have.

Magnet wire is a material used in many electronics, from headphones to large amplifiers. Magnet wire comes in a wide range of sizes for different applications. This type of wire is usually made from copper or aluminum and can be round or rectangular in shape. While not magnetic itself, magnet wire is used to link magnetic power and electrical power in the same circuit. This makes magnet wire an essential part of many types of circuits.

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Enamel

The enamel on magnet wire is the outer coating applied to the outside for better wire insulation.

I recommend: Infantron provides a guide to the types of enamel available for use with magnet wire.

Copper magnet wire

Copper magnet wire is the standard type of magnet wire on the market. Copper has a high rate of electrical conductivity and comes in a wide range of sizes for many applications.

I recommend: Wiretron provides an overview of magnet wire plus information on different sizes, thermal classes and other options available.

Aluminum magnet wire

Aluminum magnet wire is used for electronics that work on a lower rate of conductivity. Aluminum has about 60% of the conductivity of copper wire, so aluminum magnet wire is often square or rectangular in shape to permit more space.

I recommend: MWS Wire Industries provides the specifications on all standard sizes of aluminum magnet wire.

Air core coil

The air core coil is similar to an inductor, only an air core coil does not use a magnetic core. Instead of a magnetic core, the air coil can have a non-magnetic material used in place of the magnetic core or have magnet wire in a special configuration so that it does not need a core material.

I recommend: Daycounter Engineering Services provides an air core inductor calculator to determine the potential inductance of the air core coil.

Impedance

Impedance in an electronic device is the action of opposition to the flow of current in an electric circuit. Impedance, measured in ohms, is the loss of copper to the resistance of the magnet wire and losses within the magnetic and electrical fields of the circuit.

I recommend: NDT Resource Center provides an overview of impedance, diagrams and equations to factor the measurement.

Inductor

An inductor is a component in electrical devices. The inductor is used to create an electromagnetic field for completing a circuit. The inductor is made up of a magnetic core with magnet wire surrounding it.

I recommend: Lazar's Power Electronics Guide provides information on magnetics, particularly those magnetic components used in transformers and inductors.