Selecting the correct conductor size is critical to efficient magnetic design.
Undersized conductors increase losses and temperature rise. Oversized conductors may not fit within the available winding window.
This calculator helps evaluate wire sizes and current carrying capability.
Calculator
Wire Current Density Calculator
Estimate required copper area and approximate AWG size from RMS current and target current density.
Total Copper Area Required: mm²
Area Per Conductor: mm²
Approximate Suggested AWG:
This is a first-pass estimate. Real winding design also requires insulation diameter, window fill, AC loss, bend radius, and thermal checks.
Want optimized winding and CAD output?
Start Design AnalysisUnderstanding the Results
Explain:
- AWG
- Diameter
- Cross-sectional area
- Current density
SolidMag Engineering Note
The lowest resistance conductor is not always the best solution. Designers must balance wire size, fill factor, manufacturability, and cost.
Related Reading
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