A Comprehensive Guide to Micro-Coils

Micro coils are electromagnetic coils that are extremely small in size where interaction occurs between electric currents and magnetic fields. The production of a micro-coil involves the winding process of an electrical conductor wire in order to develop the shape of a spiral, coil, or helix. However, depending on the purpose of use, the shape and dimensions of the electromagnetic coils can differ. In order to determine the shape and size of a micro coil, the designer needs to consider several parameters such as the strength of the desired magnetic field, inductance, and resistance. Due to the tine size, in order to prepare the micro-coils, the manufacturers require to use a microscope or magnifying glass for the preparation of the coils.

In several devices such as electromagnets, inductors, transformers, and sensor coils, micro coils are essential to developing the interaction between magnetic fields and electric currents. In order to conduct the interaction, either a magnetic field can be generated by passing an electric current through the wire, or an electric current is generated in the conductor by passing an external magnetic field through the interior of the coil.

Challenges Due to the size of Micro Coils:

In the case of invasive medical devices where micro coils are essential parts, the manufacturers and designers face a significant challenge to fit the micro-coils into the devices due to their physical size. The demand for the smaller micro coils is increasing day by day as the demand for miniaturized components such as transducers and sensors is increasing. Therefore, the manufacturers require to use positioning systems and state-of-the-art micro motion control in the manufacturing process of micro coils.

Manufacturing Challenges:

The production of a micro-coil requires ultra-fine wires of nearly eight microns in diameter. Due to this smaller size, traditional methods and machinery are not useful to wind and connect ultra-fine wires. Instead, the manufacturing process requires custom methods and machinery.

Ultra-fine Wires Connection:

In order to overcome connectivity challenges, modern manufacturers use thermo-pressure bonding technology. This is an innovative technology that helps to connect both similar and different ultra-fine wires. Even if a wire is twelve times thicker than the other or is made of different metals, the thermo-pressure bonding technology is effective to connect those ultra-fine wires. This technology is not only effective to build durable products such as permanent medical implants but also offers strain-free, corrosion-free, and high reliable joints.

Ultra-fine Wires Winding Process:

The winding process of ultra-fine wires is the basis of the production of micro coils. Therefore, to conduct an effective winding process, manufacturers need to have custom micro-coil winding machinery. Especially, in the case of medical applications, micro coils should be built on the basis of quality standards and tight tolerances.

Applications of Micro Coils:

Micro coils and ultra-fine wire connectivity are essential in several applications such as-

Active Implants: In order to prepare the stimulation components of the brain, pain management devices, and to control and monitor pacemakers, micro coils have an effective role.
Navigation and Orientation Sensors: Micro coils are also useful for stent positioning, targeted radiation catheters, highly accurate ablations, targeted drug delivery, implanted markers, and endoscopic manipulation.
Therapeutic Applications: To prepare the devices for electrophysiology treatments and electricity-based ablation, micro-coils are essential.
Diagnostic: Micro coils are also necessary to prepare miniature sensor implants for wireless communication.
In the case of dental and orthopedic treatments where pulsed electromagnets are used, micro-coils have significant applications.

The Future of Micro Coils:

Micro coils have opened the door of new possibilities for the designers of invasive medical devices and other industries. The necessity of accessing high-density body regions without affecting the functioning of the body is increasing tremendously. On the other hand, the demand for less energy consumption and the long life span of the implanted devices is growing. For these reasons, the demand for ultra-fine technologies and micro coils is increasing. Thus, there is a great future ahead for micro-coils and ultra-fine wire technology.