Enamelled resistance wire  is a specialized type of enamelled wire (magnet wire) engineered exclusively for resistance-centric applications. It retains the fundamental structure of traditional enamelled wire—featuring a metal conductor encapsulated in a thin, uniform insulating enamel layer—while prioritizing three core performance metrics: stable electrical resistance, exceptional heat resistance, and reliable load-bearing capacity.

Unlike standard enamelled wire, which is optimized for maximum electrical conductivity, enamelled resistance wire uses high-purity resistance alloys as conductors. These alloys are precisely formulated to deliver controlled resistance values, enabling critical functions such as precise current limiting, accurate temperature sensing, and efficient resistance heating. The “enamelled” insulation layer is not merely a protective barrier; it is a high-performance coating cured at extreme temperatures to withstand the significant heat generated during resistance operation (often exceeding 300°C), preventing short circuits and ensuring long-term stability in precision electrical and thermal devices.

Core Specifications of Our Enamelled Resistance Wire

Parameter	Details & Options	Key Advantages
Conductor Material	Constantan (Cu-Ni 45/55), Nichrome (Ni-Cr 80/20, Ni-Cr 60/15), Fe-Cr-Al (Cr20Al5)	Alloy composition optimized for low TCR (±30ppm/°C max), anti-oxidation, and long service life
Insulation Layer	Polyimide (PI, 200-260°C), Ceramic (400-500°C), Glass Fiber (300-450°C)	High dielectric strength (≥15kV/mm), moisture resistance, and mechanical wear resistance
Resistance Range	0.1Ω/m - 100Ω/m (customizable to 200Ω/m for special applications)	Precision tolerance (±0.1% to ±5%) to meet diverse engineering requirements
Conductor Diameter	0.05mm - 3.0mm (ultra-fine options down to 0.03mm for microelectronics)	Flexible for both miniaturized components (e.g., sensor coils) and high-power heating elements
Operating Temperature	-50°C to 500°C (continuous use); up to 600°C for short-duration peak loads	Stable performance in extreme cold (e.g., aerospace environments) and high-heat industrial settings

Main Types of Our Enamelled Resistance Wire

Constantan Enamelled Wire: Boasts an ultra-low temperature coefficient of resistance (TCR: ±20ppm/°C) and excellent long-term stability. Ideal for precision resistors, current shunts in power meters, temperature compensation modules in automotive electronics, and load resistors in communication devices. Its Cu-Ni alloy composition ensures minimal resistance drift even after 10,000 hours of operation.

Nichrome Enamelled Wire: Delivers high specific resistance (1.0-1.5Ω·mm²/m) and superior oxidation resistance at elevated temperatures. Widely used in heating elements such as 3D printer hotends, small household heaters, laboratory incubators, and industrial drying equipment. It maintains structural integrity up to 450°C, making it suitable for continuous heating applications.

Fe-Cr-Al Enamelled Wire: Offers a cost-effective alternative with high temperature resistance (up to 500°C) and excellent mechanical strength. Perfect for household appliances like hair dryers, electric stoves, and toasters, as well as industrial heating systems such as pipeline heaters and thermal treatment furnaces. Its Cr20Al5 alloy provides strong corrosion resistance against most industrial gases.

Precision Enamelled Resistance Wire: Engineered with resistance tolerance as low as ±0.1% and tight diameter control (±0.001mm). Tailored for high-end applications including aerospace avionics, medical diagnostic equipment (e.g., MRI machines), precision electronic instruments, and semiconductor manufacturing tools. It undergoes strict quality control to ensure consistency across every spool.

Key Applications

Our enamelled resistance wire caters to a wide range of industries, leveraging its specialized performance to drive innovation:

Electrical Components: Precision resistors, potentiometers, current sensors, temperature detectors, and voltage dividers in consumer electronics and industrial controllers.

Heating Equipment: Miniature heaters, thermal printers, electric blankets, industrial high-temperature furnaces, and 3D printing accessories.

Automotive & Aerospace: Engine temperature sensors, battery management systems (BMS) for electric vehicles, aircraft cabin heating components, and hydraulic system heaters.

Medical Dvices: Dental curing lights, blood analyzer heating elements, physical therapy equipment, and precision temperature-controlled incubators for laboratory use.

Renewable Energy: Solar inverter temperature monitoring modules and wind turbine generator current limiting components.

Why Choose Our Enamelled Resistance Wire?

Stable Resistance Performance: Conductors are made from vacuum-melted alloys with strict impurity control (01%), ensuring minimal resistance drift (% over 5,000 hours) across temperature variations.

Superior Heat & Corrosion Resistance: Insulation materials are sourced from top global suppliers, undergoing 500+ hours of high-temperature aging tests to guarantee no cracking or degradation.

Flexible Customization: We support tailored solutions for resistance value, conductor diameter, insulation type, and spool length (from 100m to 10,000m), with fast prototype development (7-10 working days).

Reliable Quality Assurance: All products pass UL, IEC, and GB certifications, with 100% inspection during production (including resistance testing, insulation breakdown voltage testing, and diameter measurement).

Technical Support: Our engineering team provides professional application guidance, helping customers select the optimal product for their specific use cases and resolving technical issues promptly.