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Verdampfer & Coils

Winding wire - materials, thicknesses and safe winding

Coil wire guide: Kanthal, nichrome, SS316 and nickel in comparison. Everything about wire thickness, resistance and safe winding of your coils in the e-cigarette.

Coil wire is the heart of every self-built atomiser and plays a decisive role in determining the flavour, vapour production and safety of your setup. Whether you’re building your own coils for the first time or looking to optimise them, the material, wire gauge and winding technique determine how your e-liquid tastes and how consistently the coil performs. The following guide explains the most important types of wire for e-cigarettes, shows you what to look out for when buying, and gives you specific pointers on resistance, wattage and durability. This way, you can make informed decisions instead of blindly following trends.

Wicking wire is a thin metal wire used to make the heating coil in a rebuildable atomiser (RDA, RTA or RDTA). As soon as current flows from the battery mod, this heating wire in the e-cigarette heats up and vaporises the e-liquid, which is transported to the coil via cotton.

Typical diameters range from 0.2 mm (AWG 32) to 0.5 mm (AWG 24). Thinner wire heats up faster and is suitable for mouth-to-lung setups, whilst thicker wire retains more heat and is suitable for sub-ohm builds. Distinction: A ready-made coil is wire that has already been wound to a specific resistance. Winding wire, on the other hand, is sold in spools by the metre, and you form the coil yourself – usually around a mandrel with a diameter of 2.5 to 3.5 mm. The resulting resistance in ohms depends on the material, wire gauge and number of turns.

Each material has its own electrical properties and target temperature. The four common variants:

Kanthal (FeCrAl)

Kanthal wire is the classic choice for beginners. The iron-chromium-aluminium alloy is dimensionally stable, inexpensive and forgiving of winding errors. Kanthal operates exclusively in Watt mode (Power Mode). Typical resistances: 0.4 to 1.2 ohms.

Nichrome (Ni80)

Nichrome contains 80% nickel and 20% chromium. It heats up around 25% faster than Kanthal and delivers a slightly more intense flavour. Less dimensionally stable, but popular with experienced coil builders. Also operates in Watt Mode only.

Stainless steel SS316L

SS316L is the all-rounder: works in Watt Mode and Temperature Control Mode (TC). Neutral in flavour, corrosion-resistant and food-safe. A good choice if you want to experiment with TC.

Nickel (Ni200) and Titanium

Both are pure TC wires and must never be used in wattage mode – risk of overheating. They are specialist materials for users with TC-compatible mods.

Before you go out to buy coil wire, clarify these points:

  • Suitable mode: Does your mod use wattage mode or TC? Kanthal or Ni80 are fine for wattage; for TC, you need SS316L, Ni200 or titanium.
  • Wire gauge (AWG): 0.3 mm (AWG 28) is the all-round standard. For tight MTL coils, use 0.25 mm; for sub-ohm clouds, use 0.4 mm or braided variants such as Clapton.
  • Resistance range of your device: Check the minimum ohm rating of the mod. If you coil too low, the device will throttle or shut down.
  • Purity and origin: Reputable manufacturers specify the alloy and diameter precisely. Cheap wire from an unclear source may contain impurities.
  • Length per spool: 5 to 10 metres is sufficient for beginners. Those who build a lot of coils opt for 30-metre spools.

Common mistakes: Using nickel in watt mode, choosing wire that is too thin for high wattages, or firing coils directly on the battery without an ohmmeter. Take the time to measure the resistance with an ohmmeter or a regulated mod before taking your first puff.

Which build wire is best for beginners?

Kanthal A1 in 0.3 mm (AWG 28). It retains its shape well, is forgiving of winding errors, is affordable and works in any wattage mode device. This will allow you to gain some initial experience before switching to Ni80 or exotic wires.

How many turns should my coil have?

Typically 5 to 8 turns with 0.3 mm wire and a 2.5 mm build rod. Depending on the material, this results in around 0.8 to 1.2 ohms. For sub-ohm setups with thicker wire, you’ll need fewer turns.

Can I use any wire in temperature control mode?

No. Only SS316L, Ni200 and titanium work in TC mode because their resistance increases with temperature. Kanthal and Ni80 have too constant a resistance and would be read incorrectly in TC mode.

How long does a wire coil last?

One to three weeks with normal use. Sweet e-liquids with a high sugar content significantly shorten the lifespan. As soon as the flavour changes or the coil is visibly encrusted, you should re-build it.

Building wire gives you control over the resistance, heat output and flavour profile of your e-cigarette – provided you choose the material and gauge to suit your mod. Kanthal and Ni80 for Watt mode, SS316L for flexible use, Ni200 and titanium only for experienced TC users. If you’re ready to build your own coils, you’ll find the right wires, tools and spare parts in our selection of coils and building accessories. Take your time to compare, start with a simple alloy and gradually work your way up to more advanced builds.

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