Thick Wire – What is it in Vaping?

Definition

Thick wire refers to any coil-building wire with a larger-than-average diameter—usually 24 AWG or lower—that is used in rebuildable atomisers, tank RDAs and RTAs to create low-resistance, high-mass coils. Its main purpose is to generate more heat and surface area so that more e-liquid is vaporised per second, producing bigger clouds and a warmer, denser vape. Beginners often equate “thick wire” with “cloud chasing wire,” but it also plays a role in Temperature Control (TC) setups and in smoothing out Hit“>throat hit for high-VG juices.

Technical Details

How Thick Wire Works

Electrical resistance is inversely proportional to cross-sectional area; therefore, a thicker wire has lower resistance per unit length. A single 22 AWG Kanthal A1 strand has roughly 0.52 Ω per foot, whereas 26 AWG sits at 1.28 Ω. Lower resistance allows higher wattage without excessive voltage, ramping up faster and staying hotter longer.

Common Gauges & Materials

  • 24–20 AWG Kanthal A1 – most common for power mode
  • 22–20 AWG Nichrome 80 – faster ramp-up, lower resistance
  • 22–18 AWGTitanium Wire – used in TC mode; must be run only in TC
  • Flattened variants (ribbon, staggered fused claptons) – combine thick core with thin wrap for flavour/cloud balance

Usage & Tips

  • Wicking: Thick coils drink juice quickly—use generous Cotton“>organic cotton and opt for Top Fill tanks to avoid dry hits.
  • Battery Safety”>Battery Safety: Low-resistance builds pull high amperage; verify your cells are rated for the continuous discharge required.
  • Ramp-up: Pre-heat coils gently before final wicking to eliminate hotspots and reduce metallic taste.
  • Common Problem: Slow ramp-up on single-battery mechs—try Nichrome 80 or staggered clapton cores to balance resistance and mass.

History & Context

When early vapers moved from cig-a-likes to rebuildables around 2012, 28–32 AWG was the norm. As box mods grew to 50–200 W, builders chased lower builds, pushing wire gauges thicker each year. The 2015 “cloud comp” scene cemented 20–22 AWG as standard, while modern mesh strips and framed staples represent the next evolution in maximising surface area without further increasing wire diameter.

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