How to Use Enamelled Copper Wire for PCB Repair

By Kunkune | Published: 2026-10-25

Category: How-to Guides

Learn how to repair broken PCB traces using 0.1mm enamelled copper wire. This guide covers preparation, soldering technique, and common mistakes to avoid.

Quick answer

Use 0.1mm enamelled copper wire to bridge damaged PCB traces by tinning the wire ends, placing it over the broken trace, and soldering both ends. The enamel burns off at soldering heat, so no stripping is needed.

Why enamelled copper wire works for PCB repair

Enamelled copper wire is coated with a thin insulating layer that burns away when heated by a soldering iron. This means you can place the wire directly on a PCB trace without manually stripping insulation. The 0.1mm diameter is thin enough to fit alongside existing traces without causing shorts.

The main trade-off is that the enamel can leave a small residue that may affect solder adhesion if not fully burned off. A clean, hot iron tip and proper flux help ensure a solid joint.

Limitations of this method

This technique is best for repairing single traces or small gaps. For large damaged areas or multi-layer boards, consider using conductive epoxy or replacing the entire board. The 0.1mm wire is not suitable for carrying high current—use thicker wire for power traces.

Step-by-step PCB trace repair

Prepare the damaged trace: Clean the broken trace area with isopropyl alcohol. Use a scalpel or fine sandpaper to remove any oxidation from the exposed copper ends. Apply a small amount of flux to both ends of the break. Skipping cleaning can cause poor solder adhesion, leading to a weak repair.
Tin the wire ends: Cut a piece of 0.1mm enamelled copper wire about 2 cm longer than the gap. Touch the wire end to a hot, tinned soldering iron tip. The enamel will burn off and the wire will take a thin coating of solder. Repeat for the other end. Do not hold the iron on the wire for more than 2 seconds—excess heat can melt the wire or damage nearby PCB components.
Position and solder the wire: Place the tinned wire over the broken trace, aligning each end with the exposed copper. Hold the wire in place with tweezers. Touch the iron tip to one end until the solder flows, then repeat for the other end. The wire should lie flat against the board. If the wire lifts, apply a tiny dab of solder paste or flux under the wire before reheating.
Trim and inspect: Use flush cutters to trim excess wire close to the solder joints. Inspect the repair under magnification—look for gaps, solder bridges to adjacent traces, or leftover enamel residue. Clean any residue with alcohol. A magnifying lamp or jeweler's loupe helps spot problems that are invisible to the naked eye.

Product facts

0.1mm Enamelled Copper Wire 10m – 5pcs Pack for PCB Repair: 0.1mm enamelled copper wire, 5 reels of 10m. Enamel burns off at soldering heat so no stripping. For PCB trace repair and winding coils. This wire lets you repair fine PCB traces quickly without stripping insulation, saving time and reducing the risk of damage to nearby components.
0.1mm Enamelled Copper Wire 10m – 5pcs Pack for PCB Repair