Ribbon Wire – What is it in Vaping?

Definition

Ribbon wire is a flat, ribbon-shaped heating element used in rebuildable atomisers such as RDAs, RTAs and RDTAs. Unlike traditional round wire, the flattened profile creates a larger surface area that touches the cottonwick, allowing more e-liquid to vaporise at once. This design boosts flavour intensity and cloud production while maintaining moderate resistance. Ribbon wire is usually made from temperature-resistant alloys like Nichrome 80, Kanthal A1 or stainless-steel SS316L, and is sold on spools for vapers who prefer to build their own refillable coils.

Technical Details

Technically, ribbon wire is manufactured by cold-rolling round wire into a precise rectangular cross-section. Typical dimensions range from 0.1 mm × 0.8 mm up to 0.4 mm × 1.2 mm; the first number is thickness, the second is width. Because the flat geometry increases surface area without dramatically raising mass, it heats up quickly and cools down faster than equivalent round wire, reducing ramp-up time. Ribbon wire is available in standard resistances: Kanthal A1 delivers steady wattage, Nichrome 80 offers quicker ramp-up, and SS316L enables both wattage and temperature-control modes. Common variations include staggered ribbon (claptoned with round wire) and parallel ribbon stacks that create intricate coil builds like framed staples or alien coils, balancing low resistance with dense vapour.

Usage & Tips

• Installation: Cut ribbon wire with sharp flush cutters to avoid burrs; align the flat side flush against cotton for maximum contact.
• Wicking: Use slightly more cotton than with round wire—enough to fill the coil but still slide with light resistance—to prevent hot spots.
• Common Problems: Uneven glow indicates hotspots; gently pinch and strum the coil while pulsing at low wattage to even it out.
• Safety: Always check resistance on an Ohm Reader”>ohm reader before firing; ribbon wire’s low mass can read lower than expected on hybrid mechs.

History & Context

Ribbon wire gained popularity in the mid-2010s when Australian cloud-chasers sought denser vapour from RDAs without excessive heat. Originally borrowed from industrial heating elements, the vaping community refined alloys and dimensions, making ribbon wire a staple in modern sub-ohm building.