Speaker Lead Wire
Speaker Lead Wire
Built for swing performance, which is the actual failure mode in a driver lead.
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Industry application
Audio, Speakers And Earphones
Lead-out wire and internal cable for drivers, headphones and in-ear monitors, where the conductor moves with the diaphragm.
Context
What This Industry Asks Of A Conductor
Audio is where conductor flex life stops being a specification and becomes the product. A driver lead moves every time the diaphragm does, for the whole service life of the speaker, and it has to do that while staying light enough not to load the moving assembly and consistent enough that two channels measure the same. Speakers are one of the fields where we help customers design conductors that differentiate them from their competitors, and the tinsel wire construction is why: winding foil over a soft textile fiber core greatly improves bending strength and tensile strength against a solid wire of comparable size, at a low specific gravity.
Requirements
The Constraints That Actually Govern
Industry pain points
- Lead-out wires fatigue and open-circuit before the driver wears out.
- Adding conductor mass changes how the diaphragm behaves.
- Resistance variation across a production lot shows up as channel imbalance.
- Fine conductors will not take solder cleanly on rework.
What the conductor has to deliver
- Swing performance rated to the excursion life of the driver.
- A resistance target held tightly across a lot.
- Low specific gravity on the moving assembly.
- A plated surface that solders the same way every time.
Recommended
Conductors We Supply Into Audio, Speakers And Earphones
Tinsel Wire
Bare Copper Tinsel Wire
Highest conductivity per unit of foil in the range, with no plating layer in the current path.
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Tinsel Wire
Silver-Plated Tinsel Wire
Silver surface for demanding termination and contact requirements.
View specifications
Tinsel Wire
Silver-Plated Alloy Tinsel Wire
Silver-copper alloy foil with silver plating: strength and surface both at the top of the range.
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Delivery
Scenarios And Supply
Typical application scenarios
- Loudspeaker driver lead-out
- In-ear monitor internal wiring
- Headphone cable flex sections
- Automotive speaker assemblies
What we deliver alongside the conductor
- Sample testing on both conventional and customized products, with no minimum order quantity.
- Two production shifts running without interruption so orders leave on time.
- Technical staff available 24/7 for immediate support and engineering advice.
- A comprehensive loading report supplied with every shipment.
Process
From Your Targets To Repeat Production
1
Requirement
You send the conductor resistance, outer diameter, tensile strength, swing life and soldering method. All five are treated as one problem.
2
Material selection
Foil and base metal chosen from bare copper, oxygen-free copper and the tin-copper, iron-copper, silver-copper, nickel-chromium, nickel-iron and copper-nickel alloys.
3
Core and plating
Fiber core picked for working temperature and abrasion; tin, silver or nickel plating specified at 0.3 um to 2 um.
4
Sampling
We build and test a sample. No minimum order quantity applies to conventional or customized sampling.
5
Verification
Resistance, tensile strength and elongation are measured on our own equipment, with salt spray where corrosion matters.
6
Production and shipment
Two shifts keep delivery on schedule, and a comprehensive loading report goes out with every shipment.
Reference
Related Engineering Guides
technical guide
What Tinsel Wire Is, And Why It Outlasts Solid Wire Where Cables Bend
The construction, the materials and the reason a foil-over-fiber conductor beats a solid wire of the same size on flex life.
Read the guide
material guide
Choosing The Fiber Core: Aramid, Liquid Crystal Polymer And The Alternatives
What each fiber core actually gives a tinsel wire, and which service conditions should point you at which one.
Read the guide
Questions
Audio, Speakers And Earphones: Frequently Asked Questions
Can you match the lead wire we use today?
Send the conductor resistance, outer diameter, tensile strength and swing requirement, along with how it is soldered. Those are exactly the performance requirements we customize against.
Do you supply to in-ear monitor makers as well as speaker plants?
Yes. In-ear monitor is one of the application areas listed for our conductors, alongside speaker, mobile device and automotive.
Building Cable For Audio, Speakers And Earphones?
Send the performance targets your conductor has to meet. We will propose a construction and sample it with no minimum order quantity.