Why is Copper Flat Wire So Important

Copper wires are the most reliable and popular for use in electrical appliances and goods. It is the favorite for the electricians and technical people dealing with any type of wiring. People have always been used to the round wires and cables having been used since ages. However, as technology developed, the need for something more flexible arose. The copper flat wire was development sometime close to the mid-20th century to address this requirement. This brought about significant changes in the way copper wires could be used ushering in ease of use, improved performance, reliability, and wider acceptance.


Why copper

1. Copper is the most used element in various industries like in the construction as plumbing, electric wiring, roofing etc. There are various reasons for people relying on copper for electrical purposes. These include

2. Copper is an excellent conductor of electricity. Only silver surpasses copper in terms of electrical conductivity, but it is expensive on one side and does not have so many attributes.

3. It is robust, resistant to abrasion, heat resistant, and can withstand adverse climatic conditions. There is a frequent rise or fall in the temperature in electrical lines. Copper can sustain fluctuations.

4. The metal is durable, flexible, and very ductile. It can be stretched, molded into any form, and still retain its strength.

5. Copper is available in different forms and is mixed with other metals to form highly efficient alloys. It can be customized and used as per your needs for connectors, braided tapes, cables etc.

Copper flexible connectors are made from silver-plated, tinned, and bare copper wires. Several industries depend on these connectors for use as joints to connect bus bars. Foils of electrolytic copper are stacked together, and electric current is applied under high pressure. They are widely applied in VCB, bus ducts, switchgear industries, resistance welding engineering, power plants, electric locomotives etc.

What makes flat wires and cables popular:

Versatile and reliable

There are numerous ways the copper flat wire is used for wiring needs such as low-voltage lighting, data, audio, video, HDMI, and highly efficient in streamlining a worn-out home theatre system that requires revamping. Flat wires adapt very well to all types of surfaces. They can be installed easily. You just need to push and press, it sticks firmly. You can bend it, fold it, stretch it, use it anywhere without worrying about its strength or durability. it removes all the complications that are associated with the round wires and cables.

Weight saving

The use of flat wires often reduces the overall weight of the product. Tapes, fillers, insulation etc, adds up to the weight of the product. It is strong by itself and does not require any large conductors for strength. The current load can be carried with much lower cross-sections managing voltage drops.


Applications that require movement like drawers, Axis-control equipments, medical diagnostic appliances, robotics, doors, rotating arms, and similar need flexibility in all the tools. The way the copper flat wire can be bent and applied with minimum wiring errors while eliminating malfunction risks.

High-Density Interconnections

Flat wires achieve better cabling density than the normal other conventional cables. They are more effective for higher conductor applications than the round wires or cables.

Space optimization

When the need of fillers, insulations, tapes etc., is not there, it automatically reduces not only the weight but creates more space for the copper flat wire. It can be stacked and layered in any manner ensuring there is no wastage of space.

How to choose the copper flat wire when coating is required

The above-mentioned properties define the flexibility and suppleness of the flat wires. This increases its usage among different applications. Certain applications require maximum flexibility. So, it is important to check the shielding material that is being used. The conductor must be left open or have exposure rather than be under cover to ensure strong bonding. It will also reduce the risk of conductor movement. Alignment is preserved when the movement is lessened.   Silicon rubber should be tried as they can provide more flexibility than the PVC insulation. It is necessary to ensure the jacketing material must be hard and should not succumb to wear and tear while in motion.

How to Choose your Wire Manufacturers

It is not necessary that a cable and wire manufacturer has the same capability as the other manufacturer. Their services may differ based on the size, dimensions, price, and of course quality.  The wire manufacturers differ in their expertise and finding one who has the capabilities to provide products as required by you can be time-consuming unless you are ready with the information they would require, and you are prepared with your questions.


What you must know about your requirements:

1. The design: Determine the type of wire you need, whether you need it to for a new setup or is there a previous existing design that you need to improvise. If it is the latter, you must inform the suppliers when it was installed, its cost, brand, and the quality. If it is for a new setup, ask for quotes from different wire manufacturers, negotiate, check for quality, their ability to scale in case you require more, the return policy for any leftover material etc.

2. Technical points: This might include the power the cable needs to deliver, number of contact points, voltage, grounding, the type of signal, its speed, the type of connectors you will need etc.  If you are sure of what you need, it will save plenty of time and money. In case you are not comfortable with the technicalities, the manufacturers have their specialists who can help you determine and provide a customized solution.

3. Quality concerns: It is important for you to inform the manufacturer the purpose and where you will be using the wire. While most of the wire manufacturers use copper because of its amazing properties, you must make sure they are corrosion -resistant, durable, can withstand heat, moisture, and other calamities. These are the general requirements. If your requirement is for some hospital or health concerned, the equipment may need frequent sterilization or washing. Such specific points must be informed in advance so that they build the product accordingly using different technologies.

Why wire manufacturers prefer copper

Copper, as mentioned, has many remarkable properties.

  • It is a good conductor, can be molded in many ways, and is far less expensive than silver, the other metal which offers superior conductivity.
  • Wires are used everywhere- overhead, underground, in buildings, external wiring and in almost all electrical and electronic items that requires wiring.
  • Copper is durable, robust, and gives longevity to all products it is used in. It can sustain all types of extremities- heat, rain, any other outage without causing any risks to life.
  • Copper is either used in its raw form or at times, mixed with other elements like aluminum, nickel, lead, tin, and more.

Manufacturer’s Certifications:

Almost all manufacturers are available online with their website. They display their licenses and certifications in a prominent corner or in the About Us page. This is practically seen in every business website with licenses and certification from their respective industries. For the wire manufacturers the most important certificate is the ISO (International Organization for Standardization). It is recognized all over the world and applies to most industries. The certificate ensures the reputation of the supplier. It confirms that the products are of high-quality and they meet all the safety measures that are required. This is important since you are talking about products that can cause fire and destroy both property and lives. In India there are other registrations to be done like the SSI and NSIC.

Because they maintain the quality and safety standards most of the manufacturers and supplier have their clients from the international market. The Indian copper manufacturer usually carries a copper wire exporter license. They have an IEC code number and is a registered member of the Federation of Indian Export Organization (FIEO). They ensure the material they supply is tested several times before it is released into the market.

Industries where copper wire is vastly used

The competition is growing in the wire manufacturing industry. The wire manufacturers while ensuring the quality cannot afford to price their products high. Copper wire is used in the making of biometric scanners which nowadays are important for identification while entering most of the places that require high security. It is used in industries like telecommunication, aerospace, defense, and every electrical appliance used in homes.

Why is the Bare Copper Strip Preferable?

The bare copper strip is extensively used because of its high conductivity. As compared to other metals which are available, copper appears to be the leading conductor and this is why it is invariably the first choice for manufacturers of electrical products and appliances. The bunched copper wire is made up of many strands of copper wires which are braided together. These can also be twisted and tweaked easily and offer many advantages.

Bare Copper Wire Continue reading

Should You Buy the Enamelled Copper Wire?

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Why Do You Need the Glass Wire?

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Why You Need Nickel Copper Alloy?

There is a lot of demand for the nickel copper alloy which is mainly used for marine application. The reason behind using the nickel copper alloy in such cases is because the alloy is highly resistant to marine water corrosion. These alloys continue to provide an effective solution for all kinds of technological challenges today. When nickel is added to copper it can improve its strength and resistance power to corrosion. At the same time, the alloy continues to be ductile. You can even add other materials to such alloys to enhance its robustness, corrosion-resistance, castability and weldability. Like the nickel copper alloy, the PVC wire is another product which is becoming popular for wiring for safety reasons.

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How Can You Benefit from Flat Copper Wire?

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How Special Cables Make Wiring Safer and Effective

Copper wires have always been used for making special cables which can be used for transmitting electric power safely. Conductors are nothing buy physical mediums which can carry electrical energy from one point to another and these happen to be key components of both underground and overhead power distribution and transmission systems. You can choose a conductor depending on efficiency and price. The best conductors will be able to guarantee maximum electrical conductivity. In this sense, copper wires are the best choice because they have exceptionally high electrical and thermal conductivity. They also have high tensile strength which is capable of withstanding mechanical stresses. Continue reading