High-Frequency Litz Wires for Tomorrow's Automation
High-Performance Industrial Solutions
Modern industrial electronics demand maximum power density and efficiency. New semiconductor technologies such as SiC and GaN are driving up switching frequencies. HF litz wires from PACK LitzWire minimize skin and proximity effects and enable compact, high-performance inductive components for tomorrow's automation.
In switch-mode power supplies, sensors, or drive systems, our HF litz wires ensure stable electrical properties and thermal robustness for smooth, highly automated series production and efficient industrial processes.
We supply high-quality HF litz wires to manufacturers for:
- Lifting and positioning systems
- Power transmission components
Reproducible Quality for Your Series Production
In industrial electronics, consistency over thousands of units is the decisive factor for process reliability.
- Quality Guaranteed by Our Owner-Managed Company
From raw copper to the end product, we control every step at our German production facility to eliminate fluctuations in material quality. - Scientific Design Support
With RuPaFox® and LiWiCalc®, we support you starting in the design phase to find the scientifically founded, optimal litz wire construction. - Maximum Delivery Reliability
Through our high vertical integration, we act independently of global supply chain risks and secure your production planning. - Future-Oriented Materials
We continuously research new material combinations to be ready for the next generation of power electronics (SiC/GaN).
Material Research for Advanced Power Classes
The introduction of new switching technologies and the increase in power density require continuous adjustments in insulation materials and litz wire constructions. Standard solutions quickly reach their limits with modern requirements.
PACK LitzWire consistently invests in:
- Researching new material combinations
- Testing insulation films and enamelled wire coatings for their resistance to partial discharges and high thermal loads
These insights flow into our manufacturing and enable us to offer HF litz wires that withstand the highest loads.
The requirements in industrial electronics are as diverse as the applications themselves. PACK LitzWire develops individual solutions in close coordination with customers that push the boundaries of technology – from miniaturization in sensors to efficiency increases in large drives.
PACK LitzWire supported an industrial customer in revising switch-mode power supply transformers to save installation space and increase efficiency at frequencies above 100 kHz. Through the use of fine-strand RUPALIT® HF litz wires and additional film insulation, AC losses could be significantly reduced and standards such as EN 62368 and EN 61558 safely met. The result: A more compact, thermally robust transformer with higher power density.
In bifilar transformer windings, mix-ups of start and end often led to errors in assembly. PACK LitzWire solved this through color-coded coverings (e.g., white and colored), which enable clear identification of the strands. This eliminated assembly errors, lowered the reject rate, and significantly accelerated the winding process without affecting the electrical properties.
For extremely flat planar coils in induction cooktops, PACK LitzWire developed a solution with profiled HF litz wires and high-temperature enamels (≥ 200 °C). The exact dimensioning and profiling maximized the fill factor with minimal build height. The coils remained voltage-proof and odorless even under continuous load and after pressing – ideal for automated series production.
High switching frequencies of modern inverters cause massive eddy current losses in electric motors. In workshops, PACK LitzWire analyzed the interactions and designed a litz wire structure that minimizes these AC losses. The optimized winding enabled a more compact design with the same power and measurably increased the efficiency of the entire drivetrain.
For automated guided vehicles (AGV) with inductive charging, PACK LitzWire optimized the transfer coils for the use of SiC/GaN inverters. Despite large air gaps and high frequencies, the thermal load could be controlled through simulation-supported design (LiWiCalc®) and extremely fine single wires. This allowed for a significant reduction in component size with a simultaneous efficiency increase.
For functional sensor clothing, PACK LitzWire developed extremely flexible litz wires made of high-strength alloys (copper-silver). With the finest single wires (0.025 mm), polyurethane enamel, and a resistant nylon covering, the litz wire withstands washing processes and permanent bending cycles without breaking. The result is durable, comfortable smart textiles.
To maintain the range of sensors despite miniaturization, the quality factor (Q) had to be maximized. PACK LitzWire reduced the outer diameter of the litz wire to a minimum through optimized enamel layers and adapted silk insulation, increasing the copper fill factor in the limited winding window. The result: More powerful sensors with the same or reduced size.
PACK LitzWire supported an industrial customer in revising switch-mode power supply transformers to save installation space and increase efficiency at frequencies above 100 kHz. Through the use of fine-strand RUPALIT® HF litz wires and additional film insulation, AC losses could be significantly reduced and standards such as EN 62368 and EN 61558 safely met. The result: A more compact, thermally robust transformer with higher power density.
In bifilar transformer windings, mix-ups of start and end often led to errors in assembly. PACK LitzWire solved this through color-coded coverings (e.g., white and colored), which enable clear identification of the strands. This eliminated assembly errors, lowered the reject rate, and significantly accelerated the winding process without affecting the electrical properties.
For extremely flat planar coils in induction cooktops, PACK LitzWire developed a solution with profiled HF litz wires and high-temperature enamels (≥ 200 °C). The exact dimensioning and profiling maximized the fill factor with minimal build height. The coils remained voltage-proof and odorless even under continuous load and after pressing – ideal for automated series production.
High switching frequencies of modern inverters cause massive eddy current losses in electric motors. In workshops, PACK LitzWire analyzed the interactions and designed a litz wire structure that minimizes these AC losses. The optimized winding enabled a more compact design with the same power and measurably increased the efficiency of the entire drivetrain.
For automated guided vehicles (AGV) with inductive charging, PACK LitzWire optimized the transfer coils for the use of SiC/GaN inverters. Despite large air gaps and high frequencies, the thermal load could be controlled through simulation-supported design (LiWiCalc®) and extremely fine single wires. This allowed for a significant reduction in component size with a simultaneous efficiency increase.
For functional sensor clothing, PACK LitzWire developed extremely flexible litz wires made of high-strength alloys (copper-silver). With the finest single wires (0.025 mm), polyurethane enamel, and a resistant nylon covering, the litz wire withstands washing processes and permanent bending cycles without breaking. The result is durable, comfortable smart textiles.
To maintain the range of sensors despite miniaturization, the quality factor (Q) had to be maximized. PACK LitzWire reduced the outer diameter of the litz wire to a minimum through optimized enamel layers and adapted silk insulation, increasing the copper fill factor in the limited winding window. The result: More powerful sensors with the same or reduced size.
Innovation through Customized HF Litz Wires
- Increase in power density through profiled litz wire geometries for compact components.
- Increase in process reliability in your series production through color-coded HF litz wires.
- Simulation of your winding with LiWiCalc® for precise loss minimization.
