As every application area has a unique set of requirements, therefore, the need for custom-made devices is increasing. When it comes to manufacturing micro-coils, different customers have different requirements to perfectly match the needs of the application area. Therefore, manufacturers need to take a unique approach to design and developing custom-made coils. In this article, we will discuss how manufacturers manage the custom coil winding process during the production of custom-made micro-coils.
What Is Custom Coil Winding Process?
With the help of a custom coil winding process, manufacturers produce custom-made micro-coils to meet the requirements of the customers. For the production of custom coils, a manufacturing company should take an inclusive approach in order to build specific models. When you are preparing micro-coils for precision instruments, medical devices, or scientific activities, specific models are essential. Along, with this, manufacturing should employ experienced professionals for this job.
The unique factor of the custom-made coils is their different shapes and sizes. When the customers specify their requirements regarding the shape of the micro-coils, manufacturers follow the specifications. Therefore, they can build rectangular elliptical, circular, and even coreless coils depending on the specifications.
The custom coil winding process is basically the winding or twisting of the thin wires around a pin or core. Customers may also specify the necessary layers during the winding process and based on that, the winding process can be done in two different ways, such as single-layer winding and multi-layer winding. The number of winding wires also varies and depending on that there are two types of coils, such as bifilar coils and ordinary coils. Manufacturers use a single wire to produce an ordinary coil through a single-layer winding process. Conversely, the use of two parallel wires is necessary for the production of bifilar coils. However, these two wires have to be isolated during the winding process.
A manufacturing company is responsible for maintaining the precise dimensions of the custom-made micro-coils. Therefore, careful calculation of inner and outer dimensions is necessary to design the custom coils. Most micro-coils have 400-1000 windings and are 0.8 mm in width. To maintain this tiny width despite the large winding numbers, manufacturers use ultra-fine wires of 9 microns in diameter. As the wire can be 5 to 12 times thinner compared to human hair, manufacturers should use proprietary equipment.
Applications of Custom Coils:
A long list of medical devices and other technical devices include custom coils as the necessary component of the device. The major applications of the custom coils are-
- To prepare multiple invasive devices, such as medical devices, end devices of electrophysiological treatments and electricity-based ablations, and miniature implants, custom coils are useful.
- Custom coils serve various applications in the toroid, such as fast and reliable PCB assembly, filtering, and noise reduction.
- To produce various types of transformers, including current transformers, chokes, high voltage and low-frequency transformers, grid transformers, and low voltage and high-frequency transformers.
- Custom coils are essential for the production of various scientific and laboratory equipment.
- To manufacture devices for various measurements, induction heating, and electromagnetic pulses, custom coils play a crucial role.
What Criteria Does a Manufacturing Company Have to Manage Custom Coil Winding Process?
A manufacturing company should build specialized equipment as well as have effective knowledge and skill to use the equipment during the winding process. Along with this, manufacturing should also take an efficient technological approach.
An ideal coil manufacturing company should be able to meet the following requirements-
- During the winding process, the manufacturing company needs to use high-notch technological equipment.
- The company should employ professional and experienced employees for this job.
- The manufacturing company should have the ability to produce frames of various shapes.
- High-speed order fulfilment is another important requirement that a company should offer through mass production facilities.
- It is also important to maintain the high quality of the micro-coils.
Along with fulfilling these requirements, a manufacturing company should also use the most effective techniques to connect the thin conductive wires. While the traditional methods of soldering and welding can not provide efficient connections between the wires, thermal compression bonding technology is the most efficient method for building connections between two tiny ultra-fine wires. This method is also appropriate for joining two wires with different diameters.
