You might have to make a die set to pull the round wire through. Possibly with flat rollers to squeeze the wire flat. You have to make sure the enamel coating is not broken and might have to repaint it.
One key tool in Lansing/Altec speaker production was a thing which milled round wire into "flat" wire just before winding.
Yes, ~~half your copper/Al is scrapped but VCs must be VERY light so it isn't a big cost. Half of 70 grams at $3/pound is, what? 23 cents? On a $200 speaker?
No, I do not know how to build a both-sides micro-miller.
I have seen copper ribbon for transformers (>10 years ago) but not really right-sized and the price was frightening.
Yes, ~~half your copper/Al is scrapped but VCs must be VERY light so it isn't a big cost. Half of 70 grams at $3/pound is, what? 23 cents? On a $200 speaker?
No, I do not know how to build a both-sides micro-miller.
I have seen copper ribbon for transformers (>10 years ago) but not really right-sized and the price was frightening.
Drawing or milling flat wire in small quantities would need lots of expensive tooling, as the wire would be delicate.
Ask a speaker repair expert, they might have a source.
And you have made coils before?
That also needs some experience.
Ask a speaker repair expert, they might have a source.
And you have made coils before?
That also needs some experience.
I have made a wire flattening mill for very thin wires, see here. It was not an easy task, but I can flatten 0.12mm wire down to 0.05mm for example. If you send me your wire I can try to flatten it for you! I am located in Europe, though...
Interesting, the rolling part of the equipment seems straightforward, and in diy amounts the whole spooling thing wouldn't really be necessary. What about insulation. I think originally I may have read it was anodized
The spooler actually is part of a music string winder (I make strings), and some strings require flat wires, hence the effort to get a bit more wire flattened... The complicated part was to get the spooling in sync with the mill as the wire is so subtle it breaks as soon as speeds get out of sync. Therefore I programmed the controller to adjust speed according to spool diameter (which increases with every new layer on the spool), plus a magnetic decoupling system to dampen the tension on the flattened wire etc. etc. - so if very soft wires need to be flattened it's not easy to get it done properly...
For small amounts of wire you can try to use a pasta maker ( = kitchen device to make noodles), or if funds allow a small jewelry rolling mill.
As for insulation: flattening would probably break the varnish, in that case you would need to re-varnish it. But maybe it's possible to feed the wire through a hot air blower to soften the varnish prior to milling so that it gets through undamaged...?
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