Flat Wire – What is it in Vaping?
Flat Wire – Comprehensive Glossary Entry
Definition
Flat wire is a type of resistance wire that has been pressed from the traditional round profile into a flat, ribbon-like strip. In vaping, it is used to build coils in rebuildable atomisers (RDAs, RTAs, RDTAs) and is prized for creating a larger surface area that touches the wick. This increased contact improves e-liquid absorption and produces denser flavor and thicker vapour compared to standard round wire, while still keeping builds simple for beginners.
Technical Details
Flat wire is usually made from Kanthal A1, Ni80, or SS316L and is measured in millimetres for width and thickness—common sizes range from 0.1 mm × 0.8 mm up to 0.3 mm × 1.5 mm. Because the cross-section is rectangular, resistance is lower than an equivalent gauge of round wire, so builders often use an extra wrap or two to hit target ohms. Variations include ribbon wire (ultra-thin) and stacked flat wire that forms the core of exotic builds such as Fused Claptons. When paired with Nicotine“>freebase nicotine e-liquids, the rapid ramp-up of flat wire can deliver bold flavour without overheating the juice.
Usage & Tips
- Wicking: Lay cotton snugly against the flat faces to prevent flooding or dry hits; the wide contact patch wicks faster than round wire.
- Bending: Use ceramic tweezers to gently shape the coil—sharp kinks can crack the wire and create hotspots.
- Resistance check: Always dry-burn at low wattage (10–15 W) to check for even glow; hotspots can shorten coil life.
- Safety: Ensure the coil’s resistance is within your mod’s limits before filling via the Port“>fill port; flat wire’s low resistance can dip below safe thresholds if over-wrapped.
History & Context
Flat wire entered the vaping scene around 2014 as builders sought simpler alternatives to twisted and Clapton coils. Its ease of use and flavour gains quickly made it a staple in the Australian rebuildable community, especially among vapers chasing bold flavor without the complexity of multi-core exotic coils.