The Wire Gauge Selector helps determine the correct AWG or mm² wire size based on current, system voltage,
cable length and allowed voltage drop. This ensures efficient power delivery and prevents overheating in DC applications.
How Wire Gauge Selection Works
When current flows through a conductor, voltage is lost due to resistance. Thicker wires reduce resistance
and voltage drop. This calculator uses current, distance and drop limits to estimate the wire gauge
required for safe operation.
Where This Calculator Is Useful
- eBike power wiring
- EV conversions
- Battery packs
- Solar DC wiring
- 12V/24V/48V systems
- DC power distribution
Industry Wire Recommendations
- Low voltage cables require acceptable voltage drop (2–3%)
- Long cables should use thicker gauge
- High current circuits need oversized wires
Frequently Asked Questions
Q: What is acceptable voltage drop?
Most DC wiring should target 2–3% drop for good efficiency and safe performance.
Q: Should I oversize the wire?
Oversizing reduces heat, improves efficiency and is recommended for long distance wiring.
Q: Does current matter more than voltage?
Current defines heating and is the primary factor in wire selection, voltage matters mainly for drop percentage.
Q: Can I use this for solar and eBike wiring?
Yes, this calculator supports low-voltage DC applications including solar, EVs and eBike systems.
Q: Does AWG correlate directly to mm²?
Yes, each AWG size has a known cross-sectional area in mm² which the calculator provides.
