New Alloy: Inconel® 617 is now available from Alloy Wire. Learn about Inconel® 617

List of Alloys & profiles

List of Alloys & profiles
Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 1

Electrical Resistance Wire & Hot Cutting Wire

Electrical resistance wire for heating elements, resistors and heat sealing packaging machines. Also, High Strength Hot Cutting wire for foam cutting, plus ‘Hot and Cold Cutting Wire Assemblies’ for durability and strength at high temperature.

If you’re looking to calculate the resistivity of your wire, please use our Resistance Wire Calculator to quickly and easily calculate your wires resistance to a current.

Heating Element Guidance

Electrical resistance wire is widely used in heating elements in a number of applications. The following calculations give a guide to selecting an electrical resistance wire for your application.

Overview – heating element guidance and calculation

An introduction to electrical resistance of flat and round wire, a calculation of element resistance and a temperature-resistance table for 80/20 NiCr.

Surface area loading

Heating element for a variety of applications and a guide to the appliance, element type and suggested surface loading range.

Round wire heating elements

A guide to calculations necessary for calculating element resistance for a variety of applications.

Coiled or spiral elements

A table and diagrams allowing the user to locate the most suited round wire and diameter to form a close wound coil.

Flat wire heating elements

Calculations and examples for flat wire elements.

Conversion factors

Conversions between imperial and metric.

Ohms law

An overview, diagram and calculation reminders.

Resistance Wire Stock Sizes

A table of resistance wire stock sizes for reference.

All information is given for guidance purposes only. For specific heating element or resistor design please consult a qualified electrical design engineer.

Foam/EPS Cutting

We can now supply the complete ‘hot cutting’ wire assembly for Industrial Foam/EPS cutting machines as an alternative to the customer buying direct from the Original Equipment Manufacturer (OEM).

At this stage, we are limited in our design and assembly components.

The good news is we can send you a sample of our wire assembly for you to promote and for customers to see our design work. We are also keen for you to send customer samples for us to check and assess feasibility.

Electrical Resistance Wire range

Hot Cutting & Sealing range

Alloy Wire manufacturer and stock wire and flat wire for hot wire cutting, plastic bag sealing and heating elements.

You are welcome to purchase the exact quantity of wire for your application. Our resources have allowed us to develop wires for specific industries that perform even better than the standard product.

Please ask about alternatives that may be more cost effective and durable.

  • Element wires for heat sealers & impulse sealers
  • Vacuum sealing
  • ‘T’ profile heat sealing & impulse sealing
  • Plastic bag welding
  • Wire for L sealers
  • Hot cutting wires for foam (EPS)
  • Electric heating elements
  • Electrical resistors
  • Order quantities from 10 ft to 10000 Lbs
Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 7

Large size range from .001” (0.025mm) to 0.827” (21mm)

We operate from two state-of-the-art factories which, with continual investment in the latest technology and machinery, produce precision wire sizes from .001″ (0.025mm) to .827″ (21mm) in small batches and medium volumes.

Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 8

Order Quantity ranging from 3 metres to 3 tonnes

We manufacture the wire you require in the quantity you require it. Our world class manufacturing performance gives you a flexible order quantity ranging from 3 meters to 3 tonnes, meaning you only pay for what you need.

Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 9
Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 10

Delivery within 2 weeks

Our lead times are short because we stock in excess of 200 tonnes of more than 60 ‘High Performance’ alloys and, if your finished wire is not available from stock, we can manufacture within 2 weeks to your exact specification.

Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 11

Manufacturing wire, bars and rope in 60 Exotic alloys

We are the world leading manufacturer of precision drawn round wire, flat wire, profile wire, bars and wire rope in more than 60 different ‘High Performance’ nickel alloys, also known as ‘Exotic’ alloys.

Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 12
Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 13

Order is manufactured to your specification

We produce round wire, flat wire, shaped wire and wire rope to your exact specification and in exactly the quantity you are looking for. With a range of 60 Exotic Alloys available, we can provide the ideal alloy wire with specialist properties best suited to your chosen application.

Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 14

Our ‘Emergency Manufacturing Service’ for delivery within days

Our usual delivery times are 2 weeks, however if an urgent order is required, our Emergency Manufacturing Service ensures your wire is manufactured within days and shipped to your door via the fastest route possible.

Contact us so we can better understand you

Every customer has their own needs, their own standards to adhere to and their own projects with unique specifications. Alloy Wire is a partner in finding the right solution first time.

Ask a question, request information or enquire whichever way best suits you. Live chat with an expert, use any of our forms or contact us by phone or email.

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      Specify your shape


      Wire Size

      Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 15Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 16
      Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 17Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 18
      Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 19Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 18
      Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 21Electrical Resistance Wire & Hot Cutting Wire - Alloy Wire International 16


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      Tensile strength / hardness values


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