The custom coil manufacturing process focuses on meeting the requirements of the customers and preparing micro-coils suitable for a specific application area. In medical and electronics fields, micro-coils have a variety of applications.
Some application areas are so critical that clients specify certain requirements, including specific electromagnetic properties for the coils.
Therefore, a custom coil manufacturer needs to consider the customer’s requirements regarding the desired strength of the electromagnetic field, inductance levels, and other electromagnetic properties while designing and building the micro-coils.
Electromagnetic micro-coils have numerous applications, from building solar panels to medically invasive equipment. The custom coil manufacturing process involves built-in-house equipment and specialized manufacturing methods to meet customer requirements precisely and maintain high standards.
Requirements for Custom-Made Coil Manufacturing
- First of all, a custom coil manufacturer should have effective experience and knowledge to employ advanced coil manufacturing processes and the ability to build technical equipment from scratch for a specific application area.
- Professional and experienced coil winding specialists should conduct the coil manufacturing process. They should be able to handle different issues that arise during the coil manufacturing process.
- Different application areas require different shapes and sizes for the micro-coils. Therefore, a custom coil manufacturer should be able to design and build the coils with different sizes and shapes.
- The use of automated machinery, mass production process, and high-speed production capacity are some other essential criteria for the custom coil production process. While mass production facilities are useful for quickly building micro-coils in large quantities, the use of automated machinery is helpful in eliminating human errors.
- Finally, a custom coil manufacturer should be able to produce top-quality micro-coil while maintaining ultra-strict tolerance requirements.
Custom Coil Manufacturing Process
The custom coil manufacturing process starts with designing the shape and size of the coils according to the requirements of the customers.
A custom coil manufacturer needs to consider the application area and desired electrical properties to design and maintain the adequate shape and size for the coils. A little change in the dimensions can also cause a significant change in the coil’s electromagnetic properties.
Once the design is complete, the manufacturers wind ultra-fine thin wires around a pin or core to build the coil structure. Manufacturers usually use 8-micron ultra-fine wires to maintain tiny coil sizes.
They also insulate this electrically conductive wire to prevent external damage and the wire from touching itself during the winding method.
To prepare coils of different shapes, manufacturers use different support systems, such as rectangular or round support systems. Manufacturers can also remove the core or the support after the winding process to build a coreless or self-bounded coil.
There are also different coil winding methods that a manufacturer can use, such as helical coil winding, orthocyclic coil winding, and jumble or wild coil winding. Depending on the application area, manufacturers use a specific coil winding method.
Once the coil winding process is done, manufacturers conduct multiple tests to examine the quality of the micro-coils. If the coils meet high-quality standards, then manufacturers can release the final product for delivery.
