Why Thermo-Compression Bonding Method Is Essential for the Production of Micro-Coils?

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The production of micro-coils involves ultra-fine wires. During the coil winding process, manufacturers require to connect two different ultra-fine wires. Thermos-compression bonding method helps to build a connection between the wires. Whether two wires are similar or dissimilar, this method is useful for both cases and even for different materials. You can also connect an ultra-fine wire with a twelve-times thicker wire by using this method.

Traditionally, we have soldering and welding methods for connecting two metal wires. The welding method helps to join the wires together by melting them, whereas the soldering method uses a specific metal that has a lower melting point and pours the melted metal on the joints. However, you can use these two methods in the production of micro-coils. Due to the 9-micron diameter of the ultra-fine wires, the thermo-compression bonding method or the micro-soldering method is essential.

Why Do We Need Thermo-Compression Bonding Method?

Day by day, the demand for microscopic components, including sensors and transducers is significantly increasing. Therefore, the need for micro-coils and ultra-fine wires is also rising. When it comes to the production of microscopic components, effective technologies are necessary for providing connectivity between the wires. Micro-coils are also critical components of micro-motion positioning and control systems. Therefore, the coil winding method should involve efficient technologies.

If we use the traditional welding and soldering methods, we will face various constraints. The development of ultra-fine wire connections is quite challenging because of the miniature size of the wires and a variety of physical and environmental factors. Manufacturers also require to maintain the precise shape and size and meet ultra-strict tolerance necessities for the final products. While traditional methods are full of various drawbacks, we have no way other than relying on the thermos-compression bonding method.

Different Types of Connections Using Thermo-Compression Bonding Method:

You can use the thermo-compression bonding method for different connections, such as

  • For joining an ultra-fine wire with a tiny thermocouple,
  • For connecting two metals (micro-coils and the printed circuit board) by using a heavier intermediate wire.
  • For building a connection between the micro-coils or electromagnetic coils and the support system by utilizing metal-plated terminals.

More importantly, when it comes to building corrosion-free, strain-free, and highly durable connections, the thermo-compression bonding method is very much efficient. The overall manufacturing cost of this method is low compared to the traditional methods. You can utilize this method in mass production and get high-standard micro-coils for medical applications. Therefore, this method becomes very much necessary when it comes to manufacturing long-life products and disposal.

Benefits of the Thermo-Compression Bonding Method:

You can get several benefits from this method, such as-

  • In diminishing the noise level, this method is useful.
  • This method helps in relieving the strain on the joints.
  • With the help of this bonding method, you can eliminate the risks of damage to your sensitive components. Compared to the traditional welding and soldering methods, this method is quite safe.
  • The thermal bonding method offers you durable and oxidization-free connections.
  • As you can utilize this bonding method in mass production, therefore, the production cost of the micro-coils gets reduced.
  • Automated production process of this bonding method eliminates the possibility of human errors.

Traditional Methods:

Two famous connectivity solutions for metal wires are-

  • Welding method that helps to melt two metal wires by applying an electric current and joining them together.
  • Soldering method that uses external heat and filler metal and pouring the filler metal into the joint.

If you use these methods for connecting ultra-fine wires, you will face various drawbacks, such as-

  • Oxidization on the tiny wires and the joint. Therefore, the joints using these methods will not be durable.
  • Destruction of the ultra-fine wires because of indefinite heat spreading.
  • Development of the surplus physical strain on the joints. Thus, the joints will not be reliable.


Thermo-compression bonding method has plenty of applications. However, you can see the major application of this method in the micro-coil production process. When it comes to building pain management devices, devices for the treatment of electrophysiology and electricity-based ablations, pacemakers, and devices to measure blood pressure, heartbeat, and blood flow, this method is essential. Thermo-compression bonding method has also significant applications in preparing navigation and orientation sensors. Above all, this method allows medical professionals to consider various possibilities regarding the development of miniaturized devices.


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