A tinsel wire structure and a manufacturing method thereof are provided. The tinsel wire structure has a core, a conductive layer and a metal cladding layer. The core has an outer surface and defines a length direction. The conductive layer is spirally wound along the length direction on the outer surface of the core. The metal cladding layer is provided on the periphery of the conductive layer to cover the core and the conductive layer. The conductive layer is spirally wound on the outer surface of the core in a non-overlapping manner to define a gap so that the gap is spirally wound on the outer surface of the core in a non-overlapping manner. When the metal cladding layer covers the core and the conductive layer, the metal cladding layer covers the gap at the same time.