Enameled aluminum flat wire, also known as flat aluminum magnet wire, is a type of aluminum winding wire designed for high-density winding applications in motors, transformers, and EV drive systems. Compared with conventional enameled round aluminum wire, its flat cross-section helps improve slot fill factor, reduce system weight, and support automated winding production.
Chalco supports custom conductor dimensions, R-angle design, PE / PEI / PAI insulation systems, and bulk delivery for motor, transformer, and power winding projects.
Temperature rating: Class 120 / 155 / 180 / 200 / 220
Insulation system: PE / PEI / PAI (optional)
Supply capacity: Custom sizes & bulk delivery
Flat cross-section: Improves slot fill & supports automated winding
Enameled Aluminum Flat Wire Specifications
Enameled aluminum flat wire is supplied with a flat rectangular cross-section, and some sizes can be produced with near-square ratios. Rounded corners (R-angle) support winding formation and insulation protection, while multiple size options support mass production for motor and power winding projects.
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Cross-sectional dimensions
Thickness 1.0–5.6 mm; Width 2.0–16.0 mm (max 10 × 35 mm)
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Conductor corner radius (R-angle)
Rounded 0.5×thickness–1.0 mm, adjustable for winding and insulation protection
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Enameled insulation
Grade 1 / 2 / 3; Thickness 0.05–0.12 mm; optional thickened up to 0.45 mm
If you need a specific thickness, width, R-angle, coating grade, or insulation thickness, please send your required specifications. We can help confirm a suitable enameled aluminum flat wire supply plan.
Applications of Enameled Aluminum Flat Wire
Chalco enameled aluminum flat wire is widely used in motors, transformers, and industrial power systems, providing reliable insulation, dimensional consistency, and batch supply for B2B projects.
New Energy Vehicles & EV Drive Systems
Suitable for electric drive applications requiring high fill factor, thermal stability, and batch consistency.
Widely used in EV drive motors, hairpin motor windings, and new energy vehicle systems.
Industrial & High-Efficiency Motors
Designed for continuous operation and stable performance under high-load conditions.
Applicable to servo motors, variable frequency motors, and IE3–IE5 industrial high-efficiency motors.
Transformers & Power Equipment
Ensures dimensional consistency and insulation reliability for medium to large cross-section conductors.
Used in dry-type transformers, reactors, and high-current, high-power winding systems.
Industrial & Energy Systems Projects
Motors and winding systems for industrial equipment
New energy and power engineering supporting equipment
Project-based, batch conductor supply needs
If you are selecting enameled aluminum flat wire for EV motors, industrial motors, transformers, or power winding systems, please share your application requirements. We can help match the suitable conductor size, insulation system, and supply plan.
Enameled Aluminum Flat Wire Technical Performance
Enameled aluminum flat wire is designed for motor, transformer, and power winding applications that require stable insulation, reliable forming performance, and consistent batch quality. Its flat conductor structure helps improve slot fill factor, reduce system weight, and support automated winding production.
- High slot fill factor increases winding power density in limited space
- Aluminum conductor helps reduce system weight and material costs
- Flat cross-section supports heat dissipation under continuous high-load operation
- Smooth coating surface reduces winding friction and scratch risk
- Suitable for project-based supply, trial production, and mass production
The following data are typical reference values under specific test conditions. Final parameters can be adjusted according to conductor size, temperature rating, coating grade, and enamel film structure.
Coating System and Temperature Rating
- Coating type: PE / PEI / PAI optional
- Paint film grade: Grade 1 / Grade 2 / Grade 3
- Temperature rating: Class 120; Class 130/155; Class 180; Class 200/220 configurable upon request
Different coating systems and grade combinations can be selected according to temperature rise, voltage requirement, and operating environment.
Mechanical Properties
| Property | Class 120 | Class 180 | Class 200 |
| Bending along the edge (b ≤ 10 mm) | 2 × b | 4 × b | 4 × b |
| Bending along the edge (b > 10 mm) | 3 × b | 5 × b | 5 × b |
| Bending along a plane | 2 × a | 4 × a | 4 × a |
| Elongation at break | ≥32% | ≥32% | ≥32% |
| Note: b is the conductor width, and a is the conductor thickness. | |||
Electrical Performance
| Test condition | Class 120 | Class 180 | Class 200 |
| Room temperature, Grade 1 paint film | ≥1500 V | ≥1500 V | ≥1500 V |
| Room temperature, Grade 2 paint film | ≥2500 V | ≥2500 V | ≥2500 V |
| High temperature, Grade 1 paint film | ≥750 V | ≥750 V | ≥750 V |
| High temperature, Grade 2 paint film | ≥1500 V | ≥1500 V | ≥1500 V |
Chemical and Media Compatibility
| Property | Class 120 | Class 180 | Class 200 |
| Resin resistance | 5H | 3H | 4H |
| Solvent resistance | 2 h | 3 h | 4 h |
| Transformer oil | Excellent | Very good | Very good |
| Refrigerant | — | Good | Very good |
Technical performance may vary by conductor size, temperature class, coating grade, and test conditions. Share your required specifications, and we can help confirm the suitable enameled aluminum flat wire parameters for your project.
Production & Supply of Enameled Aluminum Flat Wire
Chalco supports enameled aluminum flat wire production through precision flattening and extrusion routes, covering different cross-sectional sizes for motors, transformers, EV drive systems, and power winding projects. These process options help ensure dimensional consistency, coating stability, and reliable batch delivery.
Production starts with selected aluminum conductor materials, including suitable aluminum conductor wire rod, before forming, enameling, inspection, and coil delivery.
Route 1: Precision Flattening / Rolling
Enameled round aluminum wire → Multi-stage flattening → Online inspection → Coil delivery
- Suitable for motor windings, EV drive motors, and hairpin winding applications
- Supports flat conductor forming while maintaining edge quality and coating integrity
- Allows parallel production of multiple specifications for batch orders
- Applicable to continuous operation conditions in high-efficiency motors
Route 2: Extruded Flat Conductor
Aluminum billet → Extruded flat conductor → Enameled insulation → Finished inspection → Coil delivery
- Covers medium and large cross-section enameled aluminum flat wire
- Suitable for transformers, reactors, and high-power winding systems
- Supports project-based supply and long-term production requirements
Supply Forms and Spool Options
- Spool types: PT25 / PT30 / PT35 / PT60 / PT90 / PT200 / PT270
- Single roll weight: up to 150 kg/spool
- Custom options: tapered spools and equipment-matched spool specifications
- Application fit: automatic winding, mass production, and continuous feeding conditions
Enameled Aluminum Flat Wire vs Copper Flat Wire
In motor, transformer, and power winding design, enameled aluminum flat wire and enameled copper flat wire are selected according to different design priorities. Aluminum flat wire is often preferred for weight reduction, cost control, and large-scale production, while copper flat wire is commonly used when higher conductivity and compact winding space are the main requirements.
| Comparison factor | Enameled aluminum flat wire | Enameled copper flat wire |
| Conductor density | Lower density, suitable for weight-sensitive winding systems | Higher density |
| Conductivity | Lower than copper; can be balanced through cross-section design | Higher conductivity |
| Slot fill factor | Flat structure helps improve slot fill factor and winding density | Also suitable for high slot fill flat wire designs |
| Cost structure | More cost-effective for large-scale and batch production | Higher material cost |
| Heat and continuous operation | Suitable for continuous operation under proper electrical and thermal design | Suitable for compact, high-conductivity winding designs |
| Typical application focus | Lightweight design, cost control, and mass production | High conductivity, limited installation space, and compact structure |
Selection Reference Guide
Enameled aluminum flat wire and enameled copper flat wire are not simple substitutes. The final choice should depend on current density, available winding space, weight target, cost structure, insulation requirements, and production scale.
- Choose enameled aluminum flat wire when weight reduction, material cost control, and batch supply are key project priorities.
- Choose enameled copper flat wire when higher conductivity or compact winding space is the main design requirement.
- For flat wire winding systems, both materials can meet engineering requirements through suitable conductor sizing and insulation configuration.
For motor, transformer, or EV winding projects, please provide conductor size, temperature rating, voltage requirement, and application conditions. We can help confirm whether an aluminum or copper flat wire solution is more suitable.
Enameled Aluminum Flat Wire Project Selection Guide
Chalco enameled aluminum flat wire is suitable for motor, transformer, and EV winding projects that require weight control, cost optimization, custom sizing, and stable batch supply.
After confirming conductor size, insulation grade, temperature rating, application conditions, and delivery plan, the material solution can be matched for sample testing, trial production, and mass production.
Q1: Is enameled aluminum flat wire suitable for mass production of EV motors?
A: Yes. Under proper current density and winding design, enameled aluminum flat wire can be used in EV drive motors, hairpin windings, and high-efficiency motor projects requiring stable batch supply.
Q2: Can the specifications be customized for different project stages?
A: Yes. Cross-sectional dimensions, coating grade, temperature rating, spool type, and delivery form can be matched for sample testing, trial production, and mass production.
Q3: What information is needed for selection and quotation?
A: Please provide conductor thickness and width, temperature class, coating system, voltage requirement, spool type, order quantity, and application conditions. This helps confirm the suitable enameled aluminum flat wire solution.
Q4: How do we choose between aluminum and copper flat wire?
A: Aluminum flat wire is often selected for weight reduction, cost control, and large-scale production. Copper flat wire is commonly used when higher conductivity or compact winding space is the main design priority.
For motor, transformer, or EV winding projects, submit your specifications to request a quote for enameled aluminum flat wire and receive a matched selection and supply plan.
Why Choose Chalco Enameled Aluminum Flat Wire
Chalco provides enameled aluminum flat wire for motor, transformer, EV drive, and industrial power winding projects, focusing on stable insulation performance, dimensional consistency, and reliable batch supply.
- Flat cross-section supports high slot fill factor and high-density winding design
- Aluminum conductor helps reduce system weight and control material costs
- PE / PEI / PAI insulation systems support different temperature and application requirements
- Custom dimensions, coating grades, spool types, and delivery forms are available
- Project support covers sample testing, trial production, and mass production supply
For motor or power winding projects requiring lightweight conductors, custom sizes, or stable batch delivery, Chalco can help match the suitable enameled aluminum flat wire solution.
Chalco can provide you the most comprehensive inventory of aluminum products and can also supply you customized products. Precise quotation will be provided within 24 hours.
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