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Welding Wire Calculator

Estimate how much MIG or flux-core wire to plan for a job without pretending one wire-feed setting fits every weld.

Reviewed 2026-10-07

Enter weld length and deposition estimate.
Planning tool only. Verify actual material, manufacturer data, code/WPS requirements and project conditions where applicable.
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How it works

The calculator starts with the deposited weld-metal requirement, then divides by deposition efficiency to estimate electrode consumption.

Wire needed = (Weld length × deposited metal per foot) ÷ efficiency

Common mistakes

Trying to estimate wire from project weight alone, ignoring joint size, or assuming 100% efficiency. Spatter and stub/setup losses matter.

How to improve the input

For repeat work, weigh a spool before and after a known weld length or use qualified procedure/weld-volume data. That gives a much better project-specific deposition number.

Relevant gear

Useful tools for this job

Tools that match this task — not a random product wall.

Frequently asked questions

Why does the calculator need deposited metal per foot?

Wire needed depends on joint geometry and weld size. Deposited metal per foot is a practical input that can come from procedure data, testing or weld-volume calculations.

What is deposition efficiency?

It is the fraction of consumed electrode that becomes deposited weld metal. Process, transfer mode and spatter change it.

Can I use this for purchasing spools?

Use it as a planning estimate and round up to available spool sizes with allowance for setup and leftovers.