Why Should You Call a Coil Winding Specialist?

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The use of miniaturized sensitive components, including sensors and transducers is increasing in recent times. For the production of various medical devices, especially for advanced micro-motion control and position, these tiny components are necessary. These tiny components consist of micro-coils or electromagnetic coils. Therefore, the micro-coil manufacturing process is the most crucial thing and this process requires the winding of very tiny ultra-fine wires around a support, pin, or core. A coil winding specialist knows how to work with tiny wires and prepare high-standard micro-coils. Therefore, you should always call a coil winding specialist when it comes to preparing miniaturized electromagnetic coils or micro-coils.

Winding Method:

The ultra-fine wires can be wound around different support systems, such as cylindrical or rectangular-shaped support systems to produce different shapes for the coils. However, winding the tiny wires is quite a challenging and difficult job because a variety of environmental and physical factors can affect the production process. Customers also have certain requirements regarding the size and electromagnetic value of the coils. A coil winding specialist also needs to preserve the ultra-strict tolerance limits within the micro-coils.

Because of the above-mentioned challenges, manufacturers can not use traditional coil winding techniques. However, many regular micro-coil manufacturers do not have specialized equipment and efficient technology to conduct the winding method precisely. This is why if you need specialized or medical-grade micro-coils, you should contact a specialist coil manufacturer.

Advanced Micro-Coil Production Techniques:

During the coil winding method, manufacturers use insulated wires. Therefore, they should apply some innovative coil production techniques so that the wires and their insulation layers do not get damaged. An ultra-fine wire can be up to 9 microns in diameter and is more than five times thinner than a human hair. Therefore, a manufacturer must cautiously work with these miniature wires.

The main challenge appears when the manufacturers need to contact two different ultra-fine wires for the coil winding process. If you use the traditional heat-based soldering methods for connecting these wires, you will face plenty of drawbacks, including low durability and inferior connectivity. While traditional methods have failed to connect ultra-fine wires, manufacturers have found an effective solution for connectivity issues. Now, most coil winding specialists utilize thermos-compression bonding technology for joining tiny wires. This method helps you to get rid of the drawbacks of traditional methods and evade reaching the insulation breaking point. Whether you are joining two similar ultra-fine wires or different wires (different in material and diameter), you can rely on this method in both scenarios.

Benefits of Thermo-Compression Bonding Technique:

Thermos-compression bonding technique is beneficial in various ways, such as-

  • This technique will help you in noise level reduction.
  • Micro-compression technology also relieves the strains at the wires’ joints.
  • This technique is comparatively very safe than the traditional methods and no damage will occur to the miniaturized components.
  • You can avoid oxidization on the wires and connections by using this technology. Therefore, the joints will be highly reliable.
  • As the coil winding specialists can conduct mass production with this technology, therefore, it will decrease manufacturing costs.
  • Above all, you can integrate this technology with the automated production process and eliminate the possibility of human errors.

Therefore, when you are contacting coil winding specialists, you should ask them about the technologies that they are going to use during the manufacturing process.

Examples of Joints:

You can use the thermos-compression method to get different joints, such as-

  • To join miniature copper thermocouples with tiny ultra-fine wires.
  • To build a joint between two metals, for instance, connecting the electromagnetic coils to a printed circuit board by utilizing a thicker transitional wire.
  • To develop a joint between the support system and the ultra-fine wires by utilizing metal-plated terminals.

This bonding technique can offer you highly-reliable, corrosion-free, and strain-free joints. This method is also comparatively economical and convenient for different client environments. You have to rely on this method for the production of long-life products and medical devices. Thermos-compression bonding technique has substantial applications in the production of permanent implants, orientation and navigation sensors, pulse electromagnets, pain management devices, and plenty of other medical devices, including dental, orthopedic, and therapeutic applications. A coil-winding specialist only knows how to apply this method in the production of micro-coils.


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