Thin Wire – What is it in Vaping?

Definition

Thin Wire refers to any resistance wire with a very small diameter—typically 30–38 AWG (0.25–0.10 mm)—used to build or replace heating coils in rebuildable atomisers and Coil“>stock coil heads. Because the wire’s mass is low, it heats and cools almost instantly, giving fast ramp-up, crisp flavour, and minimal power draw. Australian vapers choose thin wire when they want a stealthy, low-wattage vape that still delivers a satisfying Hit“>throat hit without draining the battery or overheating the Tank.

Technical Details

Thin Wire works by presenting a higher resistance per millimetre than thicker gauges. A 36 AWG Kanthal A1 wire, for example, measures ≈ 6.5 Ω/ft compared with 1.6 Ω/ft for 26 AWG. This allows builders to achieve target resistances (0.6–1.5 Ω) with many more wraps, increasing surface area while keeping the coil physically small. Common materials include:

  • Kanthal A1 – reliable, easy to work, no Temperature Control (TC) support
  • SS316L – can be used in wattage or TC modes, ramp-up slightly faster
  • Ni80 – lower resistance, quicker ramp, bright flavour but no TC
  • Titanium Wire – ultra-low mass, superb TC performance, must be run in TC only

Thin Wire is sold on 10 m spools or pre-cut “sticks”; vapers usually wrap 2.5 mm inner-diameter coils with 6–10 wraps for mouth-to-lung setups. When installing, handle gently—kinks or over-tightening can create hot spots that shorten coil life.

Usage & Tips

Start at 10–18 W and pulse in a dark room to check for even glow; strum or pinch gently with ceramic tweezers to eliminate hot spots. Wicking should be snug but movable: too tight chokes wicking, too loose causes spit-back. Thin Wire excels in Top Fill tanks with small build decks, but watch out for:

  • Coil deformation – support the wire while tightening screws
  • Dry hits – thin gauges vaporise liquid fast; keep cotton saturated
  • Leg snapping – leave 1–2 mm extra length when trimming to avoid stress points

Always check resistance on a Mod“>regulated mod before firing, and never exceed the manufacturer’s max wattage for your Tank.

History & Context

When rebuildables first reached Australia circa 2012, 28–32 AWG Kanthal was the norm. As mouth-to-lung and nic-salt vaping surged, vapers demanded cooler, more discreet setups; 34–38 AWG wire became mainstream, spurring local vendors to stock precision-spooled “thin” variants and pre-made micro-coils tailored for tight-draw tanks.

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