Speaker Tinsel Wire · Dynamic Conductor · Copper Foil Wire · Braided Copper Foil Wire — Engineered to Your Application Conditions
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CAPABILITY & SPECIFICATIONS

What We Can Build —
Numbers, Not Adjectives

Every figure on this page is a range we are prepared to commit to in writing. If your requirement falls outside it, tell us anyway — we will tell you honestly whether we can hold it, and in most cases we can engineer a structure that gets there.

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At a Glance

Core capability

Eight numbers that usually decide whether we fit your design.

Ranges below are production commitments. Tighter tolerance is possible on request — ask before you design around a limit.
ParameterCapabilityNote
Finished diameter from 0.05 mm Lower limit for a single-strand conductor
Conductor cross-section up to 6 mm² Multi-strand, braided and multi-layer structures
Strand count 1 – 260 Per conductor, including foil-wound tinsel strands
Single strand diameter 0.05 mm min · 0.25 mm standard Drawn and annealed in house
Conductivity 55 / 70 / 80 / 100 % IACS Set by alloy. 100% IACS = 0.017241 Ω·mm²/m at 20 °C
Continuous temperature 80 °C With silicone / heat-shrink / PVC jacket
Soldering temperature 300 °C short-term During termination, a few seconds per joint
Flex life 8,000 – 20,000 cycles R1.5 mm, ±90° (180° total), 100 g – 1 kg load
About flex life: a cycle count means nothing without the test condition. Ours is R1.5 mm bending radius, ±90° swing (180° total travel), 100 g to 1 kg load. If your product bends at a different radius or load, send the condition and we will test against it rather than quote a number that does not apply.
About conductivity and DCR: %IACS describes the alloy; the DCR your design cares about also depends on length and cross-section. At 20 °C, 100% IACS equals 0.017241 Ω·mm²/m — so a 0.20 mm² conductor measures roughly 86 Ω/km, and halving the cross-section doubles the DCR. Send us the DCR target and we work backwards to alloy and size, instead of asking you to convert.
Materials

Conductor alloys we run every day

Conductivity, heat resistance and fatigue strength trade off against each other. This is how we choose.

ConductorPlating optionsTypical use
OFC — oxygen-free copper Bare · tin · silver · nickel 100% IACS baseline; general voice-coil leads and damper leads
Cu-Sn alloy Bare · silver · tin Heat resistance and tensile strength where pure copper softens
Cu-Mg alloy
copper-magnesium (MG)		 Bare · silver High strength with good fatigue resistance; long-life dynamic leads
Cu-Ag alloy Bare · silver Balanced conductivity and strength for tweeter and micro drivers
Other alloys and nickel plating are available to order. Tell us the conductivity target and the temperature the joint will see — those two decide the alloy more often than anything else. If a datasheet quotes only an alloy name, ask for %IACS: the same "copper alloy" label can span 55% to 85%.
Structure

Structures, not just materials

The same alloy behaves completely differently depending on how it is assembled.

Tinsel — foil on a fiber core

  • Ultra-thin metal foil wound around a high-strength fiber core
  • Spreads bending stress over many foil edges instead of one metal section
  • Smallest OD and longest flex life per unit of conductivity

Stranded — 1 to 260 strands

  • Single strand from 0.05 mm, standard 0.25 mm
  • Up to 260 strands per conductor
  • Cross-section up to 6 mm²

Braided — 8 to 21 carriers

  • 8 / 12 / 13 / 16 / 17 / 21-carrier braiding machines in house
  • Core-wrapped, multi-layer and multi-parallel constructions
  • Mechanical protection with defined coverage
Finishing

Jacket and termination

What arrives at your line, not what leaves our winder.

Jacket / insulation

  • Silicone — flexible, high temperature, colour to order
  • Heat-shrink — mechanical protection at the joint area
  • PVC — general purpose, colour to order
  • Custom colours available on all three

Termination

  • Pre-tinning — uniform tin layer, ready to solder
  • Crimped terminals — for connector and terminal assemblies
  • Ultrasonic welding — for foil-heavy and multi-strand ends
  • Strip & tin, or supplied bare for your own process
Verification

How we prove it

In-house equipment — results available with every batch on request.

7Instruments in the lab: tensile, swing/flex, micro-ohmmeter, caliper, micrometer, thickness gauge, tension meter
100%Inspection of OD, DCR and breaking load on finished conductors
ISOQuality management system certified
TraceableBatch-level traceability from incoming alloy to finished spool
Tests we run: flex life (swing and bend), tensile / breaking load, DCR and conductivity, dimensional (OD, wall thickness, strand diameter). Salt spray and heat ageing are available on request.
Commercial

Ordering terms

Small enough to start a project, stable enough to run one.

500 mMinimum order quantity per item
3–5 daysEngineering sample lead time
7–15 daysVolume production lead time
27 yearsIn electroacoustics and flexible conductors
Before You Ask

What to send us for a firm quote

Five lines is enough to get a real answer instead of a catalogue page.

Send thisWhy it matters
Target OD or cross-section Fixes the strand structure and how much copper can fit
Target DCR, or conductivity Decides alloy first, size second
Flex test condition Radius, angle and load — without these a cycle count cannot be compared
Termination method Soldered, crimped or welded changes the end design and the plating
Annual volume Decides whether we quote a standard item or a dedicated run

Send us the five lines. We will answer with a structure.

No catalogue guessing — an engineer reads your requirement and comes back with a proposed conductor structure, the achievable numbers, and the test plan that proves them.

Contact Our Engineers See How We Test
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