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Flexible Copper Braided Wires
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Highly Flexible Stranded Copper Wire
Highly Flexible Stranded Copper Wire
BRIDGOLD Electric Brush Wires with Spot-Welded Ends
BRIDGOLD Electric Brush Wires with Spot-Welded Ends
BRIDGOLD Electric Brush Wires with Spot-Welded Ends

Electric Brush Wires with Spot-Welded Ends

These electric brush wires combine the proven BGTS/BGTSR highly flexible stranded copper conductors with precision spot-welded ends. The wires are manufactured from annealed Cu-ETP copper (single wire diameters from 0.05 mm to 0.12 mm) according to GB/T12970.4-2009. The capacitor-discharge welded ends provide a solid, burr-free terminal that eliminates the need for separate lugs, soldering, or crimping. Available in bare or tin-plated finish, these wires offer exceptional conductivity, bending fatigue resistance, and structural stability. The welded zone remains ductile and free from embrittlement, making them ideal for brush leads, rotor connections in micro motors, and high-frequency electronic devices where reliable, vibration-proof terminations are essential.

Insulated rigid aluminum busbars are designed for engineering practicability, featuring simple installation, high fitting accuracy and long-term maintenance-free operation, which greatly improves on-site construction efficiency. The products can be pre-processed with bending, punching, grooving and cutting according to customer drawings, realizing one-step forming and on-site direct installation without secondary processing. The standardized and neat structural size ensures high matching degree with equipment mounting holes and assembly positions, effectively shortening construction and wiring cycles. The rigid fixed structure is convenient for positioning and fixing, avoiding the tedious wiring and binding work of traditional flexible wires. In terms of later maintenance, the full-covered anti-aging insulation layer and corrosion-resistant metal base achieve long-term stable performance, without frequent inspection, maintenance and replacement. The smooth insulation surface is not easy to accumulate dust and dirt, reducing the risk of insulation leakage caused by dirt deposition. For engineering installation teams and equipment manufacturers, the high-installation-efficiency and maintenance-free features effectively save labor costs and later operation and maintenance expenses, improving the overall engineering economic benefits.

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    product description

    Technical Data

    Material: annealed Cu-ETP wires, C11000, copper content ≥ 99.95%

    Finish: bare, tin plating

    Packing Modes: in rolls, on spools or wooden drums

    Product Display

    Electric Brush Wires with Spot-Welded Ends (1)
    Electric Brush Wires with Spot-Welded Ends (3)
    Electric Brush Wires with Spot-Welded Ends (5)
    Electric Brush Wires with Spot-Welded Ends (4)
    Electric Brush Wires with Spot-Welded Ends (2)

    Type And Specification

    Type

    Single Wire Diameter  

    Elongation, not less than

    BGTS

    0.10mm (AWG38 ), 0.12mm

    18%

    BGTSX

    0.10mm (AWG38 ), 0.12mm

    15%

    BGTSR

    0.05mm (AWG44), 0.07mm(AWG41)

    15%

    Model And Meaning

    Electric Brush Wires with Spot-Welded Ends 7

    Customization Upon Request

    Single Wire Diameter: 0.10mm (AWG38 )

    Part No.

    Nominal Cross Section (mm2)

    Calculating Cross Section (mm2)

    Structure

    Calculating Outside diameter (mm)

    Max. DC Resistance at 20℃
    Ω/km

    Calculating weight(kg/km)

    Total Wire Number

    Strands×Wire Number Per Strand/Single Wire Diameter (mm)

    BGTS

    BGTSX

    BGTS(X)-6.3

    6.3

    6.24

    552

    12×46/0.12

    4.3

    2.94

    3.07

    59.1

    BGTS(X)-8

    8.0

    7.87

    696

    12×58/0.12

    4.8

    2.33

    2.44

    74.9

    BGTS(X)-10

    10

    10.04

    888

    12×74/0.12

    5.3

    1.83

    1.91

    95.1

    BGTS(X)-12.5

    12.5

    12.46

    1102

    19×58/0.12

    5.9

    1.48

    1.55

    118.5

    BGTS(X)-16

    16

    15.90

    1406

    19×74/0.12

    6.7

    1.16

    1.21

    151.2

    Single Wire Diameter: 0.10mm (AWG38 )

    Part No.

    Nominal Cross Section (mm2)

    Calculating Cross Section (mm2)

    Structure

    Calculating Outside diameter (mm)

    Max. DC Resistance at 20℃
    Ω/km

    Calculating weight(kg/km)

    Total Wire Number

    Strands×Wire Number Per Strand/Single Wire Diameter (mm)

    BGTS

    BGTSX

    BGTS(X)-1

    1

    0.99

    126

    7×18/0.10

    1.4

    18.5

    19.3

    9.5

    BGTS(X)-1.4

    1.4

    1.37

    175

    7×25/0.10

    1.7

    13.2

    13.7

    12.5

    BGTS(X)-1.5

    1.5

    1.48

    189

    7×27/0.10

    1.8

    11.9

    12.7

    14.0

    BGTS(X)-1.8

    1.8

    1.75

    224

    7×32/0.10

    2.0

    10.2

    10.7

    16.5

    BGTS(X)-2

    2

    1.98

    252

    7×36/0.10

    2.2

    9.23

    9.65

    19.5

    BGTS(X)-2.5

    2.5

    2.53

    322

    7×46/0.10

    2.4

    7.39

    7.72

    25.0

    BGTS(X)-3

    3

    2.97

    378

    7×54/0.10

    2.7

    6.16

    6.43

    29.5

    BGTS(X)-4

    4

    3.96

    504

    7×72/0.10

    2.8

    4.62

    4.83

    38.0

    BGTS(X)-5

    5

    4.94

    630

    7×90/0.12

    3.2

    3.69

    3.86

    47.6

    BGTS(X)-6

    6

    5.93

    756

    12×63/0.10

    3.7

    3.01

    3.23

    58.5

    BGTS(X)-6.3

    6.3

    6.24

    552

    12×46/0.12

    4.3

    2.94

    3.07

    59.1

    BGTS(X)-8

    8

    7.91

    1008

    12×84/0.10

    4.2

    2.33

    2.44

    75.5

    BGTS(X)-9

    9

    8.95

    1140

    12×95/0.10

    4.4

    2.05

    2.15

    87.0

    BGTS(X)-10

    10

    8.89

    1260

    12×105/0.10

    4.8

    1.83

    1.91

    97.2

    BGTS(X)-12

    12

    11.97

    1524

    12×127/0.10

    5.4

    1.50

    1.62

    117.0

    BGTS(X)-16

    16

    15.90

    2025

    15×135/0.10

    6.2

    1.16

    1.21

    156.0

    Round Type: Single Wire Diameter: 0.07mm(AWG41)

    Part No.

    Nominal Cross Section (mm²)

    Calculating Cross Section (mm²)

    Structure

    Calculating Outside diameter (mm)

    Max. DC Resistance at 20℃
    Ω/km

    Calculating weight(kg/km)

    Total Wire Number

    Strands×Wire Number Per Strand/Single Wire Diameter (mm)

    BGTSR

    BGTSRX

    BGTSR(X)-2

    2

    1.93

    504

    7×72/0.07

    2.2

    9.16

    9.65

    18.3

    1.93

    504

    7×3×24/0.07

    2.2

    9.16

    9.65

    18.6

    BGTSR(X)-3.5

    3.5

    3.47

    903

    7×3×43/0.07

    2.7

    5.35

    5.51

    33.3

    BGTSR(X)-4

    4

    4.01

    1044

    12×3×29/0.07

    2.9

    4.59

    4.83

    39.0

    4.03

    1050

    7×3×50/0.07

    3.0

    4.59

    4.83

    39.0

    BGTSR(X)-5

    5

    4.84

    1260

    7×3×60/0.07

    3.2

    3.71

    3.86

    46.5

    5.02

    1305

    15×3×29/0.07

    3.2

    3.71

    3.86

    48.5

    BGTSR(X)-6

    6

    5.65

    1470

    7×3×70/0.07

    3.6

    2.93

    3.21

    54.2

    BGTSR(X)-8

    8

    7.75

    2016

    12×3×56/0.07

    4.2

    2.33

    2.44

    73.0

    BGTSR(X)-10

    10

    9.69

    2520

    12×3×70/0.07

    4.8

    1.83

    1.91

    90.5

    BGTSR(X)-12

    12

    11.90

    3096

    12×3×86/0.07

    5.4

    1.50

    1.60

    112.2

    BGTSR(X)-16

    16

    15.34

    3990

    19×3×70/0.07

    6.2

    1.16

    1.21

    150.5

    Round Type: Single Wire Diameter: 0.05mm (AWG 44) 

    Part No.

    Nominal Cross Section (mm2)

    Calculating Cross Section (mm2)

    Structure

    Calculating Outside diameter (mm)

    Max. DC Resistance at 20℃
    Ω/km

    Calculating weight(kg/km)

    Total Wire Number

    Strands×Wire Number Per Strand/Single Wire Diameter (mm)

    BGTSR

    BGTSRX

    BGTSR(X)-1

    1

    0.99

    504

    7×3×24/0.05

    1.4

    18.5

    19.3

    9.3

    BGTSR(X)-1.3

    1.3

    1.32

    672

    7×3×32/0.05

    1.7

    14.2

    14.8

    12.5

    BGTSR(X)-1.5

    1.5

    1.48

    756

    7×3×36/0.05

    1.8

    11.9

    12.7

    14.0

    BGTSR(X)-1.8

    1.8

    1.81

    924

    7×3×44/0.05

    2.0

    10.2

    10.7

    17.5

    BGTSR(X)-2

    2

    1.98

    1008

    7×3×48/0.05

    2.2

    9.16

    9.65

    19.0

    BGTSR(X)-2.5

    2.5

    2.30

    1176

    7×3×56/0.05

    2.3

    7.39

    7.72

    22.5

    BGTSR(X)-3

    3

    2.95

    1505

    7×5×43/0.05

    2.6

    6.16

    6.43

    29.0

    BGTSR(X)-4

    4

    3.95

    2016

    12×3×56/0.05

    2.7

    4.59

    4.83

    39.0

    BGTSR(X)-5

    5

    4.94

    2520

    15×3×56/0.05

    3.2

    3.71

    3.86

    48.5

    BGTSR(X)-6

    6

    6.26

    3192

    19×3×56/0.05

    3.6

    2.93

    3.21

    60.0

    BGTSR(X)-8

    8

    8.05

    4104

    19×3×72/0.05

    4.2

    2.33

    2.44

    78.5

    BGTSR(X)-10

    10

    10.00

    5096

    7×7×104/0.05

    4.8

    1.83

    1.91

    97.0

    10.07

    5130

    19×3×90/0.05

    4.8

    1.83

    1.91

    97.8

    BGTSR(X)-12

    12

    12.08

    6156

    19×3×108/0.05

    5.4

    1.50

    1.60

    117.0

    Product Advantages

    Pre - welded ends  eliminate loose strands and reduce assembly time, ensuring consistent electrical contact in brush holders.

    Ultra - high flexibility  from micro-stranded construction (single wire down to 0.05 mm) allows tight bending radii, ideal for high‑dynamic applications.

    Excellent conductivity from high-purity Cu-ETP (≥99.95%) with low DC resistance, minimizing power loss, especially under high‑frequency or pulsed currents.

    Full compliance  with GB/T12970.4‑2009 ensures traceability and consistent quality.

    Customizable welding patterns  (single-end, double-end) available upon request.

    Operating Conditions

    Temperature range:
    –40°C to +200°C (tin-plated)

    Environment:
    Dry or moderate humidity. Avoid prolonged contact with acids, alkalis, or corrosive gases. Tin-plated version can be used in mildly corrosive environments.

    Current rating:
    Refer to the max. DC resistance values in the specification table and select the appropriate cross‑section based on actual heat dissipation of the equipment.

    Maintenance and Care

    Periodically inspect the conductor surface for oxidation, blackening, or mechanical damage, especially when used in high-humidity or chemical atmospheres.

    During installation, avoid excessive tension or kinking; keep the minimum bending radius no less than 5 times the outer diameter of the wire.

    For tin-plated products stored long‑term, use sealed packaging and store in a dry, clean environment to prevent discoloration of the tin layer.

    In high-frequency equipment, ensure that terminal crimping or soldering is secure to avoid local overheating due to high contact resistance.

    After-Sales Service

    Factory inspection reports and material certificates are provided, traceable to raw material batches.

    Technical team available to assist with selection, structural optimisation, and failure analysis.

    Small batch sample orders supported; lead time for bulk orders is usually 15–25 working days (expediting possible upon request).

    Customization Upon Request

    Zhejiang Bridgold Copper Tech Co., Ltd. is a professional leader China carbon brush wire, highly flexible copper stranded wires, highly flexible round stranded cables, flexible copper stranded wires, Flexible Copper Stranded Wires for Electric Brush manufacturers and suppliers with high quality and low price. Welcome to contact us.

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