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As the application areas are expanding, the demand for unique and suitable devices for specific applications is also increasing. For this reason, to design the micro-coils and conduct effective production processes, manufacturers require to take an appropriate approach. It has become essential for manufacturers to adopt the custom coil winding process and certain features for the design of the micro-coils.
Custom Coil Winding Process:
The custom coil winding process is the micro-coil manufacturing process on the basis of the specifications of the customers and requirements of the application areas. However, it is essential for the manufacturers to develop specific models and take a comprehensive approach in order to prepare the custom-made coils. The custom coil winding process becomes more important when it comes to preparing the devices for scientific activity, precision instruments, or medical devices. To manufacture the components of these crucial devices, manufacturers should employ experienced professionals.
The main difference among a variety of custom-made coils is their shape. The shape of the micro-coils can be spherical, elliptical, or rectangular depending on the client’s predetermined specifications. The clients can also decide whether the micro-coils will have a pin or a core or even they will be coreless.
The micro-coil production process involves a coil winding process where the manufacturers wind or twist an ultra-fine wire around a core with several turns. Depending on the layers of the ultra-fine wires around a core, the winding process can be of two types, such as a) single-layer winding, and b) multi-layer winding. There are also two different types of coils on the basis of the wound wires, such as a) Ordinary coil, and b) Bifilar coil. With the help of a single-layer winding process, manufacturers can manufacture an ordinary coil that consists of a single wire. Conversely, to manufacture the bifilar coils, manufacturers wind two parallel wires around the same core and place them next to each other. However, these two wires do not come in contact with each other during the winding process.
The maintenance of the precise dimensions is very essential to manufacture the custom-made coils. Therefore, the manufacturers should accurately and carefully measure the inner and outer dimensions of the micro-coils. A micro-coil that has about 400 windings of ultra-fine wires, should have less than 0.8 mm width. Therefore, manufacturers need to use ultra-fine wires of 9 microns diameter. This diameter is 5 to 10 times thinner in comparison to the diameter of human hair. Thus, the manufacturers should hold proprietary equipment in the micro-coil manufacturing process.
Application Areas:
To manufacture various types of devices, micro-coils have a significant role, for instance,
- To prepare the end devices in electrophysiological treatments, and electricity-based ablations and to prepare a variety of medical devices, such as miniature implants, sensors, etc.,
- In toroid, micro-coils have substantial applications from filtering to noise decrease. In order to provide fast and reliable PCB assembly in the preinstalled toroid,
- To prepare a variety of transformers, such as current transformers, low voltage, and high-frequency transformers, grid transformers, high voltage, and low-frequency transformers, chokes, etc.,
- For the preparation of laboratory equipment and scientific devices,
- In the manufacturing of various measurement devices,
- For the implementation of the induction heating functions,
- In a variety of applications where there is a need to create electromagnetic pulses.
The Qualities of a Manufacturing Company:
A manufacturing company should possess some essential qualities to conduct the custom coil winding process. However, the availability of specialized equipment is not enough to ensure the success of the manufacturing process, instead, the manufacturers should possess sufficient skills and knowledge to handle the manufacturing process and the equipment. The major requirements that the custom coil manufacturing company should fulfill are-
- There should be multiple professional and experienced employees in the manufacturing company.
- The company should have high-notch technological apparatus and machinery.
- The manufacturing company should offer different models of micro-coils and build multiple frames with different shapes.
- The ability to fulfill the high-speed order and prepare unique micro-coils is also a quite important quality that a manufacturing company should have.
- Above all, the manufacturing company should ensure the high standards and quality of the micro-coils.
When it is about preparing the most durable and reliable micro-coils, a manufacturing company should adopt efficient machinery and effective technologies.