Choosing litz wire: what you need to know

When selecting the right litz wire, it’s not just about conductivity but also about practical usability. Depending on the environment and the way the wire is stressed, a flat or round version can make all the difference in reliability and lifespan. In this blog, we explain what litz wires are, where they are used, and how to choose the right type for your situation.

What is litz wire and where is it used?

Litz wires are flexible conductors made up of multiple thin copper strands woven together into one bundle. Because the strands are individually thin and flexible, the bundle forms a cable that is far more bendable than a solid copper wire.

Litz wires are used wherever reliability, current conductivity, and flexibility are essential. You’ll find them in switchgear, for bridging potential differences in trains, metros, and trams, but also in amusement rides and heavy industry. Depending on the situation, different types of litz wires can be chosen.

Types of litz wire and their applications

Litz wires come in various forms, each with its own advantages. Depending on space, load, and environment, you may choose flat or round, tinned or bare. Below we explain the main types.

Flat litz wire

Flat litz wires are efficient in tight spaces, as they have a large contact surface and can be easily stacked. This makes them ideal in situations with limited space, such as in switch cabinets or grounding strips. Flat litz also offers a practical and reliable solution for potential equalization bridges.

Round litz wire

Cord litz: This round variant is known for its maximum flexibility, as it is braided more loosely and therefore highly bendable. It is the perfect choice for applications with a lot of movement, such as in cable chains, machinery, or moving connections in rail vehicles.
Top-braided litz: This round variant is strong and robust because it is braided tighter and more firmly. As a result, it is less flexible than cord litz, but more resistant to mechanical stress. This type is often used in fixed connections, for example in generators and transformers.

Tinned or bare: choosing the right finish

Tinned litz: These wires are coated with a thin layer of tin, protecting the copper against corrosion. This makes tinned litz ideal in damp or aggressive environments, such as rail vehicles, shipping, and outdoor installations. It is also widely used in amusement rides because of its robustness and long lifespan.
Bare litz: These wires have no tin layer and therefore offer even lower resistance. Thanks to their optimal conductivity, they are used where maximum current transfer is required, and the environment is clean and dry.

Applications of litz wire in different industries

• Switchgear construction: Flat litz is used for compact connections and grounding strips, where space savings and reliable contact are crucial.
• Rail and public transport: Cord litz is ideal for moving connections in trains, metros, and trams, as its high flexibility prevents wear and cable breakage.
• Industry: Top-braided litz is often used for fixed connections in generators and transformers, where mechanical stress and high currents meet.
• Shipping and outdoor use: Tinned litz offers extra protection against corrosion, making it highly suitable for damp or aggressive environments.
• Test setups and high-current rails: Bare litz is chosen for maximum conductivity, ensuring reliable measurements and minimal energy loss.

When should you use which type of litz wire?

In switchgear, transport, industry, or amusement rides, the choice of the right litz wire plays a decisive role. The difference between a reliable and a vulnerable installation often lies in the details.

• Choose flat when space is limited and high current loads still need to be carried.
• Go for cord when maximum flexibility is important, for example in moving connections or dynamic installations.
• Use top-braided when strength and resistance to mechanical stress are key.
• Select tinned in damp or aggressive environments where extra protection against corrosion is required.
• Apply bare in dry and clean situations where maximum conductivity and minimal resistance are critical.

With the right choice, you’ll achieve a durable, safe, and efficient installation that will remain reliable for years to come.

Need advice? get in touch

The right choice of litz wire strongly depends on the application and conditions. Vijselaar is happy to help you with a suitable solution. Contact us for personal advice!