Abstract

The objective of this work is to introduce and demonstrate a proof-of-concept feasibility of a novel and sustainable method for fabricating flat micro ribbon wires widely used in the electrification of consumer electronics, electric vehicles, and energy systems. Conventional ribbon wire production requires 10–20 wire drawing stages followed by 5–10 rolling stages, resulting in complex, energy-intensive, and resource-demanding processes. In contrast, machining operations generate large volumes of chips that pose storage, oxidation, and recycling challenges due to their high surface-to-volume ratio and contamination with lubricants and coolants. This study combines cutting and metal forming processes to produce micro flat electric wires. Commercially available inserts were used to cut aluminum 1050 workpiece materials, and the extrusion die was designed to flatten the free surface of the chips and machined in 5-axis wire EDM from a new or worn tungsten carbide insert, ensuring that the mechanical and electrical properties were compatible with standard wires. The presented technique transforms waste material generated during turning into a valuable product, producing continuous flat ribbon wires as thin as 250 µm at speeds of up to 150 m/min in a single step, with surface roughness values as low as Ra = 0.026 µm, dimensional stability within ±25 µm, microhardness reaching 135 HV, and electrical conductivity of 57.4% IACS, thereby reducing part costs, improving machining sustainability, and enhancing the competitiveness of manufacturing processes.