magnet wire
extrusion
from A to Z
Efficient magnet wire insulation for powerful e-motors and transformers
1st turnkey magnet wire extrusion line
The RA-I Magnet Wire Extrusion Line, launched in 2023, is the world’s first turnkey extrusion line for the industrial production of insulated magnet wire. Engineered for high-voltage e-mobility applications (800V and above) and transformer manufacturing, it enables consistent product quality and efficient processing.
Compared to traditional enamelling methods, the extrusion process offers:
- Higher production speeds
- Lower energy consumption
- Improved manufacturing efficiency
- Excellent product properties with one layer of high-performance plastic
From pay-off to take-up, every line component of the RA-I extrusion line has been carefully synchronized to meet the high demands of the rectangular magnet wire.
stable breakdown voltage
Extruded wires achieve stable breakdown voltage after thermal shock with just one layer of high-performance plastic.
firm adhesion
Magnet wire usually needs to be bent and twisted multiple times. The adhesion of the extruded insulation layer withstands these forces perfectly.
high temperature stability
chemical stability
superior electrical properties
mechanical stability
abrasion resistance
RA-I extrusion line for magnet wire insulation
The compact RA-I insulation line is equipped with Rosendahl’s high-performance extruder technology and a specially developed crosshead for flat conductors. The complete conductor processing unit comes mounted on a base frame, well guided and stable, to maintain tight tolerances in production. From pay-off to take-up, every line component has been carefully synchronized to meet the high demands of the rectangular hairpin wire.
The processing of high-performance polymers requires a deep understanding of the underlying process, and equipment that meets the highest demands.
Technical data
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Geared line speed up to 60 m/min
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Conductor materials Al, Cu
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Insulation material high-performance plastic (PEEK, PAEK, PEKK, PSU, PPSU, PPS, TPI)
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Wall thickness typically 0.1 - 0.25 mm
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Cross sections typically 2 - 15 mm², 8 - 55 mm²
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Thickness / width ratio 1:1.5 - 1:8
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Rosendahl Nextrom is a global leader in battery, cable & wire and optical fiber production technologies whose goal is to connect your needs with our technology. Quality, customization, product know-how and close cooperation with our partners are our core values.
Inline wall thickness scanner
The wall thickness of your magnet wire can be checked directly during production in real-time, saving time and simplifying quality control.
RLWS layer winding station
The RLWS layer winding station enables fully automated spool changes without operator intervention. A robotic arm automatically connects the end of one spool to the beginning of the next.
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Do you want to learn more about this market innovation? Are you interested in finding out what modifications are possible to meet your individual requirements? Reach out to us. We will gladly answer your questions.
