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BRIDGOLD Electric Brush Wires with Spot-Welded Ends

High-Quality Electric Brush Wires with Spot-Welded Ends from China Suppliers and Factory

Introducing our high-quality electric brush wires, manufactured in China by leading suppliers and factories. These wires feature BGTS/BGTSR highly flexible stranded copper conductors paired with precision spot-welded ends for optimal performance. Made from annealed Cu-ETP copper, with single wire diameters ranging from 0.05 mm to 0.12 mm, they conform to GB/T12970.4-2009 standards. Our wires come equipped with capacitor-discharge welded ends that offer solid, burr-free terminals, eliminating the need for separate lugs, soldering, or crimping. Available in both bare and tin-plated finishes, these electric brush wires provide exceptional conductivity, bending fatigue resistance, and structural stability. The ductility of the welded zone ensures resistance to embrittlement, making them perfect for brush leads, rotor connections in micro motors, and high-frequency electronic devices that require reliable, vibration-proof terminations. Additionally, we offer insulated rigid aluminum busbars designed for engineering practicability. These products facilitate easy installation, high fitting accuracy, and long-term maintenance-free operation, greatly enhancing on-site construction efficiency. Customizable options—such as bending, punching, grooving, and cutting—allow for one-step forming and direct on-site installation without the need for secondary processing. Our standardized structural sizes guarantee a high degree of compatibility with equipment mounting holes and assembly positions, effectively reducing construction and wiring time. The rigid structure simplifies positioning and fixing, eliminating the cumbersome wiring tasks associated with traditional flexible wires. In terms of long-term maintenance, the full-covered anti-aging insulation layer and corrosion-resistant metal base provide stable performance, minimizing the need for frequent inspections or replacements. Engineered for installation teams and equipment manufacturers, our products deliver high installation efficiency and maintenance-free benefits, resulting in significant savings on labor costs and enhancing overall engineering economic benefits. Trust our China-based suppliers and factory for your electrical connection needs.

Product Details

Technical Data

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

Finish: Bare copper, 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 Model Meaning

Customization Upon Request

Single Wire Diameter: 0.12mm

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)
Part No.	Nominal Cross Section (mm²)	Calculating Cross Section (mm²)	Total Wire Number	Strands × Wire Number Per Strand / Single Wire Dia (mm)	Calculating Outside Diameter (mm)	BGTS	BGTSX	Calculating Weight (kg/km)
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)
Part No.	Nominal Cross Section (mm²)	Calculating Cross Section (mm²)	Total Wire Number	Strands × Wire Number Per Strand / Single Wire Dia (mm)	Calculating Outside Diameter (mm)	BGTS	BGTSX	Calculating Weight (kg/km)
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)
Part No.	Nominal Cross Section (mm²)	Calculating Cross Section (mm²)	Total Wire Number	Strands × Wire Number Per Strand / Single Wire Dia (mm)	Calculating Outside Diameter (mm)	BGTSR	BGTSRX	Calculating Weight (kg/km)
BGTSR(X)-2	2	1.93	504	7×72/0.07	2.2	9.16	9.65	18.3
BGTSR(X)-2	2	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
BGTSR(X)-4	4	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
BGTSR(X)-5	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)
Part No.	Nominal Cross Section (mm²)	Calculating Cross Section (mm²)	Total Wire Number	Strands × Wire Number Per Strand / Single Wire Dia (mm)	Calculating Outside Diameter (mm)	BGTSR	BGTSRX	Calculating Weight (kg/km)
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
BGTSR(X)-10	10	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: Micro-stranded construction (single wire down to 0.05 mm) allows tight bending radii, ideal for high-dynamic applications.
Excellent conductivity: High-purity Cu-ETP (≥99.95%) with low DC resistance, minimizing power loss, especially under high-frequency or pulsed currents.
Full compliance: GB/T12970.4-2009 ensures traceability and consistent quality.
Customizable welding patterns: Single-end and double-end options 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. The 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.

Frequently Asked Questions (FAQ)

What is the primary benefit of spot-welded ends on electric brush wires?

Spot-welded ends consolidate the fine strands into a solid terminal, preventing strand fraying during carbon brush assembly, lowering contact resistance, and ensuring reliable conductivity and mechanical stability inside the brush holder.

What single wire diameters are available for flexible brush wires?

Standard single wire diameters range from 0.05 mm (AWG 44) and 0.07 mm (AWG 41) for ultra-flexible round wires (BGTSR), up to 0.10 mm (AWG 38) and 0.12 mm for standard flexible stranded wires (BGTS/BGTSX).

Can I choose between bare copper and tin-plated copper?

Yes. Bare copper provides optimal electrical conductivity, while tin plating enhances oxidation resistance and enables continuous operation in high-temperature (up to +200°C) and mildly corrosive environments.

Are custom strand configurations and dimensions supported?

Yes. Custom nominal cross-sections, outer diameters, strand counts, total length, and specific welding patterns (single-end or double-end) can be manufactured to meet exact application requirements.

What is the typical production lead time for bulk orders?

Standard bulk production takes approximately 15 to 25 working days following sample approval and specification confirmation. Expedited processing is available upon request.