Insulated thin wire for PCB repair, interconnects, trace fix, etc. - Page 1
Forum section: electronics / general

author: msimunic
author_rank: Contributor
timestamp: February 25, 2025, 10:26:58 pm
content: Hi all,I hope someone here knows where to find and buy a wire of kind is used in headphone cables (ie. in-ear cables)?That wire has insulator which melts very easily, wire has multiple strands, but very thin strands. Wire diameter is 0.2mm or less with at least 5 strands in it.It is very good when need to rework a PCB, for a PCB prototype test or design flaw fix.I've scraped that wire from ine-ear headphone cable.Also, very tiny insulated wire is used for in-ear headphone speaker (transducer), for coil that vibrate around magnet.Any idea where to buy such thin insulated wire?Thanks a lot.

author: themadhippy
author_rank: Super Contributor
timestamp: February 25, 2025, 10:40:02 pm
content: Lintz wire?

author: langwadt
author_rank: Super Contributor
timestamp: February 25, 2025, 10:42:43 pm
content: https://www.adafruit.com/product/3522

author: Smokey
author_rank: Super Contributor
timestamp: February 25, 2025, 10:45:32 pm
content: https://www.adafruit.com/product/1446?gQT=1Kynar wire wrap wire. Used to fix PCBs since the beginning of time.

author: langwadt
author_rank: Super Contributor
timestamp: February 25, 2025, 11:18:01 pm
content: Quote from: Smokey on February 25, 2025, 10:45:32 pmI find enameled wire much easier, not problems stripping, just cut to length and dip end in solder blob on iron

author: Smokey
author_rank: Super Contributor
timestamp: February 25, 2025, 11:30:10 pm
content: Quote from: langwadt on February 25, 2025, 11:18:01 pmI personally disagree, but if someone reading this does use magnet wire like this make sure you get the stuff who's enamel comes off at solder temperatures. Not all (not most?) will remove the enamel like that and you will need to physically remove it (scrape, sand, etc).

author: msimunic
author_rank: Contributor
timestamp: March 05, 2025, 06:11:58 pm
content: Quote from: Smokey on February 25, 2025, 11:30:10 pmI'm using 0.15mm diameter enameled wire. Enamel goes away from that wire, mostly without need for cleaning.For bigger diameter, 0.25mm and bigger, enamel doesn't come off so nicely. Even with JBC at 400 deg. C. :-)So, yes, I agree with you.

author: msimunic
author_rank: Contributor
timestamp: March 05, 2025, 06:16:19 pm
content: Quote from: Smokey on February 25, 2025, 10:45:32 pmYes, but somehow soldering in not easy as with copper wire.Could be due to Led-free solder.Is there a kynar wire of 0.1mm or 0.15mm diameter and with insulation that doesn't melt completely and instantly at solder temperature?

author: msimunic
author_rank: Contributor
timestamp: March 05, 2025, 06:22:06 pm
content: Thanks for answers.I will try to post a picture of wire I'm searching.The thing is, that wire from head-phone cable has insulation which melts like a butter, and mostly it goes of completely clean.It could be plain enameled wire, but very thin, less than 0.1mm dia, then enamel melts very easily.Small speakers, like in headphones, has that, very thin enameled copper wire in coil around magnet.I've never found a place to buy such thin enameled wire at distributor pages, ie. Farnell/Newark, Mouser.

author: tooki
author_rank: Super Contributor
timestamp: March 05, 2025, 06:41:15 pm
content: Quote from: msimunic on March 05, 2025, 06:11:58 pmNo matter how thin, this only works with insulation that is solderable. Many (most?) magnet wire enamel is NOT solderable, and must be removed mechanically or chemically. (Or you can burn those off, but that needs temperatures well above soldering temperatures.)

author: thm_w
author_rank: Super Contributor
timestamp: March 05, 2025, 10:42:54 pm
content: I use the adafruit enamel wire, and its easy to tin the end with normal soldering temperature. Its a bit harder if you are soldering in the middle of the wire, you might have to rub it a bit with the iron tip. I think I was using 350-365C, never went higher than that.We discussed a bit here too:https://www.eevblog.com/forum/chat/aliexpress-jump-wire/I used the solder then wiggle technique. I think adafruit had a video can't seem to find it.