Litz Wire Articles

Applications

Litz wire in induction heaters: where it sits inside the system and how it is sized

A breakdown of the power path across 5 stages: PFC inductor (3–5 kg of litz wire), inverter, RF cable (0.5–2 kg), matching RF transformer (4–8 kg — the main consumer), and inductor (1–3 kg or copper tubing). Nanocrystalline cores VITROPERM/FINEMET, water-cooled litz cable (4 variants, patents), the IGBT → SiC → GaN evolution, 30 kW SiC and 3.5 kW GaN case studies, common mistakes, and the Russian industry. Open collaboration with developers of induction equipment.

45 min read

Engineering

How to tin litz wire: 5 methods and why an ordinary soldering iron will not do

Mechanical stripping, active Ф-38Н flux based on phosphoric acid, a solder bath at 320–400 °C, hot crimping in a metal terminal, and self-soldering ПЭВТЛ-2 enamel. Temperatures, solders, the composition of ЛТИ-120, capillary rise of solder, and heat sinking. End termination tailored to the part — from 300 ₽ per end.

16 min read

Applications

Litz wire for LLC resonant converters: design per the 2025 methodology

What breaks the classic Dowell–Ferreira–Sullivan approach in a real OBC and server PSU — harmonics away from resonance, fringing field around an integrated L_r, the ZVS boundary set by C_ps. A modern workflow using 2D FEMM with a homogenized litz model, the SFD method, and joint core+winding optimization. Worked through a 3.3 kW SiC OBC project.

14 min read

Engineering

ЛЭШО wire: what it is, its designation, and modern equivalents

Decoding the designation per TU 16.К80-03-89, the construction, the limits for modern tasks, and a cross-reference table to DIADA continuously transposed litz wire grades.

14 min read

Technology

What continuously transposed litz wire is and why it beats ordinary wire

Skin effect, proximity effect, the rule of five, and the formulas for calculating mass. Why a 5×5×5 build delivers three times the Q factor of a plain 125-strand twist.

10 min read

Physics

Skin effect and proximity effect: how litz wire solves the loss problem

Why ordinary wire loses efficiency at high frequencies and how continuously transposed litz wire minimizes losses.

8 min read

Guide

How to choose a litz wire grade: temperature, insulation, cross-section shape

A practical guide to choosing among 52 grades. Criteria: operating temperature, insulation type, round or rectangular cross-section.

12 min read

Applications

Litz wire in electric motors: EV traction, PMSM, aerospace, BLDC

Five motor classes and the BLDC vs PMSM terminology framework: EV traction machines, high-speed PMSM (e-turbo, e-compressor), aerospace motors, precision steppers, and drone and medical BLDC motors. Comparison with hairpin and solid windings by R_AC/R_DC.

14 min read

Technology

Rectangular litz wire: when and why forming is needed

The economics of +20% fill, in watts and in rubles. Five applications with a multiple-fold payoff, a comparison with hairpin/CTC/Roebel/planar, and the ordering process.

10 min read

Audio Culture

Litz wire for the audiophile: what the Stereophile arguments are really about

What is physically inside Cardas Clear Beyond, Kimber Select KS-6068, Stealth Dream Petite V16, and Audio Note Lexus. Why thin litz wire automatically guarantees 4N copper. DIY assembly and a termination service using silver-bearing solder.

17 min read