Coil Winding Services

The coil winding process is an essential part of the manufacturing of micro-coils. Many manufacturing companies provide effective coil winding services including casting, wrapping, soldering, gluing, etc. This article will help you understand an overview of the coil winding process and what should a manufacturing company possess in order to conduct the winding process. In addition to this, we will also briefly explain the manufacturing process of micro-coils.

Coil Winding Process:

The coil winding process is the process of winding a wire of conductive material around a core or a pin. Before the winding process, the manufacturers need to isolate the wire through the insulation process. The whole manufacturing process of micro-coils is very difficult due to several factors.

• Due to the size constraint, the miniaturized micro-coils require very thin threads with diameters ranging from 58 AWG to 61 AWG. Therefore, the diameter of the thinnest isolated wire is 9 microns, and using this wire, manufacturers are able to manufacture micro-coils of 0.8 mm wide. These types of tiny coils are essential to produce medical devices such as catheterization where size matters a lot.
• An important part of the micro-coil winding process is the connection between two conductive wires. The most effective process that many modern manufacturers use for connecting two ultra-fine wires is ‘Thermo Pressure Bonding’ technology.
• Micro-coil winding services have prepared the ground for the device designers to consider it for numerous miniaturized applications.

How Is a Coil Made?

A coil is made by the winding process where an isolated wire is wound around a core. Sometimes, to prepare the coreless coils, manufacturers remove the core after the winding process. Coreless coils are generally smaller, and therefore, are very effective for vein insertion. When the number of windings becomes higher, for instance, 400, 600, 1000, or even 2000, the size of the coil can increase. Therefore, the manufacturers need to reduce the thickness of the wire. However, it is not an easy task to reduce the thickness of the wire because the process can lead you to the isolation breakpoint of the wire. Therefore, a manufacturing company should have the expertise and special machinery to handle the process.

• Due to the good conductivity of copper metal, the manufacturing of most coils involves insulated copper wire. However, depending on the application area, manufacturers may also use other metals.
• In the case of bifilar coils, manufacturers twist and wind two strands of the wire together. Due to this process, two parallel wires result in the reduction of the inductance. Therefore, bifilar coils are useful to prepare the devices that need efficient fill factor and higher sensitivity.

The Difference between Coils:

The coils can be different depending on the use of materials and the shape and size of the coils.

• In general, most micro-coils are copper micro-coils. However, silver, gold, titanium, aluminum, or any other conductive metal can be used to manufacture micro-coils.
• On the basis of the application area and procedure, the shape and size of the micro-coils change. However, many modern applications require very small micro-coils and the tiny size of the micro-coils makes them very expensive.

Ultra-Fine Wire Connection:

As there are other components in an application apart from the coil, therefore, it is essential to make a connection between the ultra-fine wires of the micro-coil to the terminals. It has been found that the traditional heat-based soldering methods and laser-micro-soldering methods are problematic to connect the ultra-fine wires and can result in poor conductivity, heat damage, oxidation of the connection, insolation damage, degraded connections, etc. 

To overcome the issues of traditional methods, many manufacturers use the innovative Thermo Pressure Bonding technology to connect ultra-fine wires. This technology is not only useful to connect ultra-fine wires of similar diameter but also effective to join an ultra-fine wire with another ultra-fine wire that is up to 12 times thicker than the previous wire.

When the manufacturers need to develop a terminal-based connection, they connect the wires with a gold-plated terminal. Thermo-Pressure Bonding technology not only provides molecular connections but also helps to get corrosion-free, high reliable, and strain-free connectivity. This technology also helps to reduce the overall manufacturing costs.

The demand for micro-coils is increasing significantly due to a variety of applications in the medical field. In order to prepare measurement devices in the medical field, micro-coils are important. This is because of the fact that micro-coils help to detect the physical and chemical conditions of our body.