How to Choose the Right Wire Gauge for Your RC Builds

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Introduction

Whether you're building a drone, RC plane, or a custom car, choosing the right wire gauge is essential for safety, performance, and reliability. Using the wrong wire size can lead to voltage drops, overheating, or even damage to your electronics. This guide will help UK hobbyists and makers understand how to pick the perfect wire gauge for their RC projects.

What Is Wire Gauge?

Wire gauge refers to the thickness of the wire. In the UK and many other countries, the American Wire Gauge (AWG) system is commonly used in RC and electronics. The smaller the AWG number, the thicker the wire. For example, 12 AWG is thicker than 20 AWG.

Why Does Wire Gauge Matter in RC Builds?

RC builds often draw high currents, especially during takeoff or acceleration. A wire that’s too thin can cause several issues:

  • Voltage Drop: Thin wires have higher resistance, which reduces the voltage reaching your motor or ESC.
  • Heat Build-up: Excessive current through thin wires can cause overheating, potentially melting insulation or causing shorts.
  • Reduced Efficiency: Voltage loss means less power for your motors, reducing performance.
  • Safety Risks: Overheated wires may cause fires or damage components.

How to Choose the Right Wire Gauge

Follow these steps to select the correct wire gauge for your RC project:

1. Calculate the Current Draw

Check the specifications of your motor, ESC, or battery to find the maximum current (measured in amps) your system will draw. It’s a good idea to add a safety margin, typically 20-30%, to account for peak currents.

2. Consider Wire Length

Longer wires cause more voltage drop. The total length includes both positive and negative wires, so if you have a 30cm positive wire, add 30cm for the negative wire as well.

3. Use a Wire Gauge Chart

Refer to a wire gauge chart that shows the maximum current capacity for each AWG size. Here's a simplified guide:

  • 20 AWG: up to 5 amps (short distances)
  • 18 AWG: up to 10 amps
  • 16 AWG: up to 13 amps
  • 14 AWG: up to 20 amps
  • 12 AWG: up to 30 amps

Remember, these are approximate values and can vary depending on insulation type and temperature.

4. Factor in the Application

For small micro drones or lightweight planes, thinner wires like 20-22 AWG are usually fine. Larger models or high-power setups may require 14 AWG or thicker.

Additional Tips

  • Use Silicone-Insulated Wire: Silicone wire is flexible and heat-resistant, ideal for RC applications.
  • Keep Wires Short: Minimising wire length reduces voltage drop and weight.
  • Check Connectors: Make sure your connectors match the wire gauge for a solid connection.
  • Test Your Setup: Measure voltage at the motor under load to ensure minimal drop.

Conclusion

Choosing the right wire gauge might seem tricky, but it’s straightforward once you know the current requirements and wire lengths. Always err on the side of thicker wire for safety and performance, and your RC build will thank you with reliable, efficient power delivery.

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