Litz Wire

Maximize high-frequency efficiency and eliminate parasitic eddy current losses with Frigate’s custom-engineered Litz Wire. Engineered precisely to mitigate skin and proximity effects, our tailored configurations deliver optimal thermal and electrical performance for your most demanding electromagnetic designs.

Conductor Materials

High-purity ETP Copper (CW004A) or Oxygen-Free Copper (CW008A)

Single Strand Diameter Range

0.020 mm to 0.50 mm (46 AWG to 24 AWG)

Number of Strands

2 to over 10,000 strands (custom bundled)

Insulation Types (Single Strand)

Polyurethane, Polyesterimide, Polyimide, Polyamide-imide

Thermal Class

Class B (130° C), Class F (155° C), Class H (180° C), Class N (200° C)

*Note: Listed timelines are indicative engineering windows. Actual delivery depends on raw material availability, strand count complexity, custom insulation requirements, and final factory capacity allocation.

Product Description

Frigate’s high-performance Litz Wire is custom-fabricated using individually insulated magnet wires precisely twisted in predetermined patterns to equalize the impedance of each strand. This specialized design ensures uniform current distribution across the conductor cross-section, significantly lowering AC resistance and minimizing heat generation in high-frequency applications.

Outer Wrapping / Serving

Nylon, Silk, Polyester, Nomex, or unserved bundles

Configuration Profiles

Round, Square, Rectangular (Profiled/Flattened Litz)

Operating Frequency Range

10 kHz to over 1 MHz optimization

Voltage Rating

Up to $10 kV (depending on custom insulation and serving layers)

Outer Diameter (OD) Tolerance

Down to ± 0.02 mm based on construction complexity

Solderability

Self-soldering types available (at 370° C and 470° C) or mechanical stripping required

Dielectric Breakdown Strength

Meets or exceeds IEC 60317 and NEMA MW 1000 standards

Twist Pitch / Lay Length

Custom optimized per target frequency to ensure complete field cancellation

Compliance & Certifications

RoHS compliant, REACH compliant, UL recognized insulation systems

Testing Protocols

100% continuity testing, high-pot testing, and pinhole insulation testing

Technical Advantages

By meticulously optimizing the strand geometry and twist pitch, Frigate Litz Wire drastically reduces both skin effect and proximity effect losses at elevated operating frequencies. This reduction in internal power dissipation allows engineers to design smaller, lighter magnetic components with vastly superior power densities and thermal efficiencies.

Let's Get Started

Need reliable Enclosure for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

EV Charging Infrastructure

Minimizes thermal stress and dynamic AC losses in high-frequency transformer windings for ultra-fast DC charging architectures, ensuring 98%+ efficiency.

Renewable Energy Inverters

Optimizes multi-kilowatt central and string inverters by reducing inductor losses, directly scaling up power yield and long-term system reliability.

Medical Imaging Systems

Provides ultra-stable, low-loss performance in high-frequency gradient coils and resonant circuits where precise electromagnetic fields are critical.

Aerospace & Defense

Delivers lightweight, high-power-density custom profiles for airborne power converters, auxiliary power units, and specialized radar power supplies.

Wireless Power Transfer

Enhances electromagnetic coupling efficiency in transmitter and receiver coils, maximizing energy transfer across air gaps for automated systems.

Induction Heating

Sustains continuous high-frequency, high-current loads without thermal breakdown, improving the duty cycle of industrial induction workheads.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

Solar Inverter Enclosure

units per month

Bento Boxes for D2C Segment

Units Manufactured Monthly

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Defence-Grade Cable Supply

Cost savings

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Flange Assembly for Pump

Faster Production

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Having Doubts? Our FAQ

We have a highly proprietary electromagnetic layout. Can Frigate manufacture Litz wire to our exact custom twist pitch and configuration specs?

Absolutely. Frigate specializes in custom B2B contract manufacturing. We do not just supply off-the-shelf spools; our engineers work directly with your design blueprints to customize the individual strand gauge, total strand count, twist pattern, and overall lay length to precisely match your target operating frequency and spatial constraints.

What outer insulation or serving options do you provide for high-voltage, high-thermal industrial applications?

Depending on your dielectric and mechanical requirements, we offer single or double outer servings using high-grade Nylon, Polyester, Silk, or Nomex tape. For extreme environments, we also manufacture extruded outer insulations (like ETFE, FEP, or PFA) to provide superior breakdown voltage protection and enhanced mechanical defense during automated coil winding.

How does Frigate guarantee the consistency and quality of strand insulation to prevent internal shorts?

We enforce strict quality control frameworks compliant with global industrial standards (IEC/NEMA). Every production batch undergoes continuous inline pinhole testing, high-potential voltage testing, and meticulous continuity checks to ensure that the ultra-thin insulation on every single strand remains 100% intact throughout the custom twisting and cabling process.

Can we procure sample batches or NPI (New Product Introduction) quantities before committing to a high-volume production contract?

Yes, we fully support the engineering validation phase. We offer a dedicated prototyping workflow with smaller minimum order quantities (starting at 10 kg) and accelerated lead times, allowing your team to test the custom Litz wire in your physical prototypes and validate efficiency metrics before scaling to mass manufacturing.

How do you handle termination and soldering for Litz wire configurations with high strand counts?

For configurations utilizing polyurethane-based single-strand insulations, the wire is self-soldering, meaning it can be directly dipped into a controlled solder bath (typically between 370° C and 470° C) without prior stripping. For higher thermal classes or non-solderable insulations, we can discuss custom mechanical stripping or specialized crimping solutions prior to delivery.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Components Built for Critical Performance

Engineered Products for Critical Applications

Litz Wire

Product Description

Outer Wrapping / Serving

Configuration Profiles

Operating Frequency Range

Voltage Rating

Outer Diameter (OD) Tolerance

Solderability

Dielectric Breakdown Strength

Twist Pitch / Lay Length

Compliance & Certifications

Testing Protocols

Technical Advantages

Let's Get Started

Industry Applications

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

Litz Wire

Get Latest Price

Litz Wire

Get Latest Price