What is Custom Coil Winding Process?

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In today’s world, the need for unique devices is increasing with the expansion of the application areas. Therefore, the coil manufacturers need to take a special approach in terms of the design of the micro-coils and the development of the production. The manufacturers now need to adopt certain features in the designing of the micro-coils and include a custom coil winding process.

Custom Coil Winding Process:

The custom coil winding process is a process of manufacturing micro-coils depending on the requirements of the customer and application area. In order to manufacture custom-made coils, the manufacturers should take a comprehensive approach to develop specific models. This is essential, especially, in the case of scientific activity, medical devices, or precision instruments. Only experienced professionals should engage in the development of the components of such critical devices.

The basic difference between different custom-made coils is their different shapes. On the basis of predetermined specifications, the micro-coils can be shaped rectangular, round, or elliptical. Depending on the demand of the customers, coils can be coreless or can consist of a core or pin.

The manufacturing of the micro-coils involves ultra-fine wires that are wound around a core. There are two types of winding on the basis of layers-i) single-layer winding and ii) multi-layer winding. Again, based on the number of wound wires, the micro-coils can be classified into two categories such as- i) ordinary coil and ii) bifilar coil.  The preparation of an ordinary coil involves a single wire and a single-layer winding process. On the other hand, the winding of a bifilar coil involves two parallel wires that take place next to each other around the same core. However, throughout the winding, both the parallel wires remain isolated from each other.

For the preparation of custom-made coils, it is essential to maintain precise dimensions. Therefore, the manufacturers should carefully consider both the outer and inner dimensions of the coils. The width of many micro-coils is limited to 0.8 mm that includes about 400 windings of ultra-fine wire. For this reason, the diameter of an ultra-fine wire should be about 9 microns which is 5 to 12 times thinner with respect to human hair. Therefore, the manufacturing of such tiny coils requires proprietary equipment.

Scope of Application:

Micro-coils are required to manufacture a huge number of devices. For instance,

  • In the manufacturing of different invasive medical devices such as sensors, miniature implants, end devices in electricity-based ablations, and electrophysiological treatments.
  • To serve a variety of applications in toroids, from filtering to noise reduction, in pre-installed toroids on devoted mounts for reliable and fast PCB assembly.
  • To manufacture different types of transformers such as low voltage and high-frequency transformers, high voltage and low-frequency transformers, current transformers, grid transformers, chokes, etc.
  • In the manufacturing of laboratory and scientific equipment for the purpose of several experiments.
  • To prepare the instruments for a variety of measurements.
  • In order to implement the functioning of induction heating.
  • In the applications where electromagnetic pulses are required.

What Should a Manufacturing Company Possess to Conduct Custom Coil Winding Process?

A manufacturing company can not handle a custom coil winding process only with the availability of special equipment, instead, the manufacturer should have sufficient knowledge and skill for the application of the equipment. Therefore, in providing the services of custom coil winding, besides having modern machinery, the manufacturers should take an effective technological approach.

Therefore, an ideal manufacturing company of custom coil winding should fulfill several requirements such as-
i) High-notch technological equipment should be available in the company,
ii) The manufacturing company should consist of several experienced and professional employees,
iii) The company should be able to create frames of different shapes,
iv) An ideal company should be capable of high-speed order fulfillment and preparing unique types of winding coils,
v) The quality of the micro-coils should be assured by the manufacturing company.

Besides these facilities, manufacturing should adopt an effective technology for connecting ultra-fine wires. The traditional methods of welding and soldering wires are not effective for several drawbacks. Therefore, many modern-day manufacturers use thermo-compression bonding technology to join two similar or dissimilar ultra-fine wires in diameter or material. This method protects the ultra-fine wires from any damage and makes them durable and reliable.


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