At California Fine Wire Co. we use precision rolling mills to provide flat wire with very tight dimensions. Our flat wire is used in a number of applications including lead ribbon, voice coil winding, and microelectronic interconnections. Ribbon wire can be produced in thicknesses between 0.0002″ and 0.050″, and in widths between 0.002″ and 0.100″. Other wire sizes may also be possible to produce, depending on the material and required dimensions. Typically, a flattening ratio of up to 40:1 can be achieved while still maintaining a minimum corner radius.

Rolling mills are designed to operate dry in order to produce wire with a clean, oil-free surface, which eliminates the need for secondary cleaning processes. However, for high purity applications, both ultrasonic cleaning and chemical cleaning processes are available.

Our consultants can assist customers regarding the availability of specific alloys and the ideal metal for their particular application. We carry numerous metal wire alloys including stainless steel, copper, and precious metals; that meet all applicable DFARS, REACH, and RoHs requirements. Quality testing, including tensile testing, dimensional inspection, and resistance testing, can be performed according to our certified procedures to verify conformance to customer specifications.

Wire can be processed in a range of production volumes for an array of applications throughout the defense, medical, aerospace, and electronics industries. Wire may be spooled or cut to length, as desired by the customer. All lead times are evaluated on a job by job basis. For additional information about our wire flattening capability, see the table below or contact us directly.

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Technical Advantages That Make a Difference

Flat ribbon wire gives you a few benefits that are hard to match with round wire. With a broader surface area, it can create stronger bonding contact or better electrical conductivity in limited space. It can also help reduce unwanted electromagnetic effects because its shape influences how current flows through a system.

Thickness and width control play a huge role too. Very fine dimensions can support micro-scale components without adding unnecessary bulk. Even edge quality matters — clean edges improve handling and reduce the risk of surface damage or connection issues. These details go a long way in making assemblies more reliable over time.

Choosing the Right Material for Your Project

Not every project needs the same performance features. That’s why flat ribbon wire is made from a wide range of metals and alloys. Copper might be ideal if conductivity is your top priority. Precious metals such as gold or platinum are helpful for corrosion-sensitive or medical applications. Nickel alloys serve high-temperature environments well.

The goal is to match the wire material with how the product will be used: electrical output, flexibility, thermal stability, or compatibility with other components. A quick discussion with engineering support can help narrow down the best fit without over-specifying.

Ready to Move Forward? Let’s Make It Easy

If you have drawings, dimensions, or even rough ideas, a direct conversation with a wire expert can speed everything up. You can request help choosing material, figuring out tolerances, or understanding how to scale from prototypes to volume production. Starting early also shortens the quoting process and helps avoid delays once you’re ready to build.

Contact us, share what you’re working on, and we’ll guide you through the next steps so your project keeps moving.

Flattening & Rolling Specifications

Process

Flattening
Rolling

Wire Shape

Ribbon/ Flat

Materials

Aluminum
Copper
Nickel
Nickel Alloys
Resistance Wire Alloys
Thermocouple Alloys
Gold

Silver
Platinum
Platinum Alloys
Glass Sealing Alloys
Bonding Wire
Numerous Additional Options Available

Finish

Bare

Plated

Flat Wire Width

0.0004″ to 0.10″
10 microns to 2.5 mm
Other Sizes on Request

Flattening Ratio

Up to 40:1

Wire Length

Cut Lengths: 0.125″ to 72″
No Limit on Spooled Lengths

Applications

Lead Ribbon
Voice Coil Winding
Bonding

Microelectronic Interconnects
Catheters and Other Medical Products

Production Volume

Prototype
Low Volume
High Volume

Typical Lead Time

Quoted on a Job by Job Basis

Additional Information

Industry Focus

Aerospace
Defense
Electronics

Medical
Research & Development

Industry Standards

ISO 9001 Certified
DFARS

REACH
RoHS