Braided wire has proven highly effective in shielding electronic equipment and devices from radio frequency interference (RFI) and electromagnetic interference (EMI) and improving signal fidelity. For this reason, it is preferred in various critical applications, such as those found in the automotive, aerospace, and medical industries.

International Wire is one of the largest copper and copper-alloy conductor and braided wire producers in the US, with extensive wire manufacturing experience. We can deliver various braided wire configurations to meet your unique needs and application requirements.

Braided Wire Explained

The primary purpose of braided wire is to shield electronic and telecommunications devices from EMI and RFI. This is important because interference can cause excessive signal noise and incomplete data transmission between critical equipment. In addition to EMI/RFI shielding, braided wires are also suitable for grounding applications, flexible connections, and providing mechanical protection for cables.

Braided wire can be made with different numbers of wires depending on the application and diameter required. Two common configurations are:

  • Tubular braid. Braided wires enclose the core in a circular cross-section. This round shape is useful for fitting cables into confined or tight spaces inside or around equipment or machinery. Tubular braided wires can be constructed from various wire materials, including tinned copper, nickel or silver-plated copper, bare copper, and stainless steel.
  • Flat braid. Flat braided wire is made by flattening tubular braids with a pressure roller. This makes the cable more flexible and increases its surface area. A flat braid also has lower electrical resistance, which makes it a common choice for grounding and lightning protection.

Advantages of Braided Wire

Compared to solid or stranded wire alternatives, braided wire offers many important benefits:

  • Flexibility. The crossed and woven pattern of the braided wires allows them to shift and adjust without compromising protection when the cable is bent. This also allows them to more easily wrap around corners or fit into small electrical or other enclosures.
  • Durability. The individual wires are closely spaced to enclose the core and provide a protective layer of metal. This reduces abrasion and wear in applications that are exposed to harsh operating conditions.
  • Lower electrical resistance. Braiding creates a larger cross-section of wire or, when flattened, a wider wire. This increased surface area lowers electrical resistance. Using materials that are naturally less resistant, like copper and aluminum, also helps keep resistance low. As resistance decreases, conductivity increases so the flow of electrical current is not impeded. This means less heat is generated, and operation is more energy efficient.
  • EMI shielding. Braided wire reduces EMI interference by acting as a shield, preventing external electrical noise from affecting the wire’s signal transmission. This is crucial for industries such as medical and telecommunications where signal clarity is paramount.

Braided Wire Applications

Tubular and flat braided wire are used in many industries. Some examples include:

  • Aerospace. Braided wire is used for EMI shielding for sensors, radars, and other aviation electronics, and in wiring harnesses and grounding straps.
  • Automotive. Braided wire is used in electrical and power system components, such as battery cables and grounding straps, and for EMI protection in “smart” and other connected vehicle sensors and electronic systems. The flexibility and durability of braided wire make it well-suited to the high temperatures and vibrations in vehicles.
  • Medical. Biocompatible stainless steel alloy braided wire can be easily bent to fit into compact enclosures for implantable probes, biofeedback devices, and catheters that send and receive signals with external electronic devices.

Braided Wire From International Wire

International Wire is an industry leader in braided wire manufacturing for EMI shielding and other applications. We also supply single-end and stranded wire, bus bar wires, grounding wires, and various conductors including bare copper and tin-, nickel-, and silver-plated copper. A large selection of standard products is available, along with custom design services.

Contact us with questions about our braided wire capabilities, or request a quote to discuss your application.

How To Manufacture Wire Braids

International Wire is an industry-leading wire braid engineering and manufacturing house. We offer a broad range of quality standard products and custom design services to meet the needs of many demanding applications. We have the knowledge and expertise to service a variety of applications in many different industries. Check out our extensive catalog of high-quality products!

How to Manufacture Wire Braids

Products include:

  • Single-end wire
  • Copper wire on bobbins
  • Metal and textile braided products
  • Large and fine stranded conductors: concentric and bunched
  • Rope-lay concentric and bunched cables
  • Fine wire ropes
  • Flat wire

Our extensive braids portfolio includes bare copper braids, tinned copper braids, silver-plated and nickel-plated copper braids, aluminum braids, and stainless-steel braids.

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