Chalco supplies enameled aluminum flat wire with a rectangular aluminum conductor and an insulating enamel coating for motor, transformer, and selected EV winding projects. As a flat form of aluminum winding wire, it is specified by conductor width, thickness, corner radius, and insulation build. Compared with enameled round aluminum wire, the rectangular section can support efficient winding space utilization when matched to the equipment design.
Chalco supports project-based selection of conductor dimensions, R-angle, enamel coating grades, insulation systems, and spool formats. Share your cross-sectional drawing, application, and order quantity to confirm a suitable configuration for sampling or batch supply.
Temperature rating: Class 120 / 155 / 180 / 200 / 220 (by confirmed coating system and configuration)
Insulation system: PE / PEI / PAI options; final insulation construction to be confirmed
Supply capacity: Custom cross-sectional sizes and batch orders
Flat cross-section: Defined width, thickness, R-angle and enamel build for winding design
Enameled Aluminum Flat Wire Specifications
Specify enameled aluminum flat wire by its bare-conductor thickness and width, corner radius (R-angle), and finished insulation build. Rectangular and selected near-square sections are available depending on size and process. For drawing-based procurement, confirm both the bare-conductor dimensions and the coated overall dimensions before production.
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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
Reference sizes and special configurations: The listed 1.0–5.6 mm thickness and 2.0–16.0 mm width are published reference dimensions. The 10 × 35 mm maximum is a separate special-section offering, not a guarantee that every width/thickness combination is available. Confirm dimensions and feasibility for the requested conductor section.
| RFQ parameter | Specification to provide |
| Bare aluminum conductor | Width × thickness (mm), section geometry and drawing tolerances |
| Corner geometry | Required R-angle / corner-radius definition and bending orientation |
| Enamel insulation | Coating system, grade or film build, thermal class and required finished dimensions |
| Winding and supply | Application, winding process, reel format, sample or batch quantity |
Dimensional acceptance: Specify both bare-conductor dimensions and overall insulated dimensions. The R-angle wording, film-build thickness and any heavy-build or special-size option must be confirmed against an agreed drawing or technical specification before use as purchase acceptance limits.
Enameled Aluminum Flat Wire Technical Performance
The performance of enameled aluminum flat wire is evaluated on the finished rectangular conductor. For winding procurement, the decisive checks are the conductor dimensions and resistance, insulation build, bend/film adhesion behavior, and dielectric performance under the specified test conditions. Values from round or paper-covered winding wire should not be treated as interchangeable.
Published reference values: The tables below retain the existing product data for preliminary comparison. Where the original information does not identify the test method, conductor size, sample condition or temperature, a numeric value must not be used as a universal purchase-acceptance limit. Match the selected wire configuration to an agreed standard and supplier test record before final approval.
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
Specify enamel chemistry, film grade and thermal class together with the intended finished-wire construction. Where applicable, IEC 60317-0-9 may be used as a reference for agreeing rectangular enameled aluminum winding-wire requirements; the applicable edition, size range, test methods and confirmed supply capability must be checked for the order.
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 |
Inspection focus for RFQs: Ask for the applicable finished-wire specification and the agreed results for conductor dimensions/resistance, enamel build, bending and film adhesion, dielectric properties and any required environmental or media tests. Include the actual sample condition and test temperature where relevant.
Applications of Enameled Aluminum Flat Wire
Enameled aluminum flat wire is selected for winding designs where a defined rectangular section, enamel insulation, and equipment-compatible supply form are important. Within broader electrical conductor and winding material applications, motor and transformer manufacturers should match conductor dimensions, electrical loading, bend geometry, and coating performance to the winding process. EV applications require additional forming and joining validation.
New Energy Vehicles & EV Drive Systems
Enameled aluminum flat wire supports lightweight EV motor windings and space-efficient designs.
Hairpin applications require validated bending, enamel integrity, and aluminum connections.
Industrial & High-Efficiency Motors
For industrial motor windings, a defined flat section helps designers coordinate slot geometry, conductor resistance and the winding pattern.
Key selection details are conductor width and thickness, enamel build, forming direction and reel compatibility with the winding line.
Transformers & Power Equipment
Transformer and reactor windings may use enameled rectangular aluminum conductors where the winding design calls for a specified conductor cross-section and insulated coil arrangement.
Compare the required section, winding resistance, insulation build and bend radius with the proposed wire and agreed inspection criteria.
Industrial & Energy Systems Projects
Non-standard industrial coils requiring drawing-defined rectangular aluminum winding conductors.
Insulation build and bend configuration matched to the specific coil and equipment geometry.
Sample and repeat-order planning for application-specific winding production.
For motor, transformer, or EV winding development, share your conductor drawing, application, target insulation system, spool requirements, and planned order volume. Chalco can review the requested flat-wire configuration for sampling and project supply.
Production & Supply of Enameled Aluminum Flat Wire
Chalco arranges supply of enameled aluminum flat wire for drawing-defined conductor sections and insulation builds. The production route depends on the section geometry, surface requirements and qualified enamel application process; forming and coating must be matched to the approved finished-wire specification.
Where applicable, suitable aluminum conductor wire rod is an upstream stock option. The procurement focus is the finished enameled rectangular wire, not a supply claim for drawing-feedstock wire rod.
Route 1: Precision Flattening / Rolling
Aluminum conductor stock → Rectangular section forming / rolling → Enamel insulation application → Finished-wire inspection → Coil delivery (process route subject to manufacturer confirmation)
- Flat conductor geometry is specified for the winding equipment and application.
- Corner geometry, surface condition, and insulation integrity require production validation.
- Conductor width, thickness, and dimensional tolerances are reviewed for the requested section.
- Sampling and repeat-production planning are aligned with the approved finished-wire configuration.
Route 2: Extruded Flat Conductor
Aluminum stock → Extruded rectangular conductor → Surface and dimensional preparation → Enamel insulation application → Finished inspection → Coil delivery (availability subject to conductor section and production feasibility)
- Alternative conductor-forming routes may be evaluated for selected cross-sectional requirements.
- The finished conductor and enamel system must meet the agreed drawing and inspection criteria.
- Production availability and batch terms are confirmed against the requested dimensions and order.
Process and inspection checkpoints: For the approved configuration, agree on conductor dimensions and edge geometry, enamel coverage and finished size, winding/bend behavior, electrical test criteria and coil identification for batch traceability. Inspection scope and supporting records depend on the order specification.
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
Spool type, winding direction, reel dimensions, and single-spool weight should be confirmed against the wire section and the customer's feeding equipment. Listed spool options and the maximum roll weight are configuration-dependent, rather than a guarantee that every size is supplied on every spool.
Enameled Aluminum Flat Wire vs Copper Flat Wire
Enameled aluminum flat wire and enameled copper flat wire are not direct like-for-like substitutes at the same conductor size. Aluminum offers lower conductor density, while copper provides higher electrical conductivity. Copper-clad aluminum conductors represent another material construction that requires separate review of copper-layer configuration and termination. For a winding redesign, evaluate required resistance, available winding space, conductor section, bend geometry, insulation build, and termination method together rather than comparing conductor material cost alone.
| 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 | Lower aluminum conductor material cost may support overall cost targets; finished-wire pricing depends on section, insulation and order requirements | 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 |
Engineering selection: Copper and aluminum flat conductors are not interchangeable at the same section. An aluminum redesign must account for winding resistance, available space, total coil weight, insulation, bending and termination. Both materials can use a flat geometry; flat shape alone does not remove the conductivity difference.
For an aluminum flat-wire assessment, send the target resistance or current, conductor drawing, allowable winding dimensions, temperature conditions and joining requirements. Chalco can review the enameled aluminum flat-wire options relevant to your design.
Related Winding Wire Products
Frequently Asked Questions
Can enameled aluminum flat wire be supplied to a customer drawing?
Chalco can review rectangular-section dimensions, corner radius, enamel build and insulated overall dimensions against a supplied drawing. Non-standard large sections and heavy-build coatings require configuration-specific feasibility confirmation.
What needs to be checked before a hairpin or formed-coil trial?
Review the bend direction and radius, insulation integrity after forming, required conductor resistance and aluminum joining process. Final suitability depends on the motor design and customer qualification.
Are all temperature classes and coating grades available for every flat-wire size?
No universal size-by-grade combination is claimed. Specify the wire dimensions, target thermal class and insulation requirements so the available finished-wire construction and applicable tests can be confirmed.
Can a prototype order use the same reel and acceptance criteria as repeat production?
The intended reel, coil weight, sampling plan and inspection criteria should be agreed for the selected configuration. Qualification and repeat-order requirements may differ by winding equipment and batch size.
Order Enameled Aluminum Flat Wire from Chalco
Chalco supports inquiries for enameled aluminum flat wire with rectangular or selected near-square conductor sections, project-specific enamel builds, and coil or spool supply. Orders are reviewed against the drawing, winding application and approved insulation requirements.
Send these details for quotation and technical review:
- Conductor drawing: Bare aluminum width × thickness, R-angle, section geometry, dimensions after enameling and tolerances.
- Insulation: Enamel type/grade or target build, thermal class, electrical requirements and applicable standard.
- Winding use: Motor, transformer or other coil application; bend direction/radius and any forming or joining constraints.
- Delivery format: Spool or coil requirement, reel compatibility, sample/batch quantity and destination.
- Acceptance: Required tests, inspection records and any approved-sample conditions.
Enameled Aluminum Flat Wire Pricing: Quotation depends on the aluminum conductor specification, width and thickness, enamel system and coating build, order quantity, spool or coil format, inspection requirements, and delivery destination. Custom sections and special insulation configurations are priced against the confirmed drawing and order requirements.
Chalco can review available configurations and coordinate sample, trial and batch-order requirements. Final specifications, feasibility, inspection documents and commercial terms are agreed for the selected product and order.
Send your enameled aluminum flat wire drawing, insulation specification and order quantity to request product configuration review and a quotation. Our sales team will follow up on supply options and order requirements.
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