The custom wire coil manufacturing method is about manufacturing the micro-coils by considering the requirements of customers. Therefore, it is essential to fulfilling the satisfaction of the customers by providing different types of design. There are different activities that occur during the production of custom wire coils, such as glueing, casting, wrapping, soldering, etc. manufacturers also require unique tools and equipment for the preparation of finished products. A manufacturing company also requires to have some essential expertise for the production of miniature coils. Modern manufacturers mainly focus on fulfilling the requirements of the customers and maintaining the quality of the wire coils effectively.

The Production Process of the Custom Wire Coils:

The foundation of the production of the custom wire coils is the winding of insulated wires around a core. If the customers require coreless coils, then the manufacturers withdraw the cores after the winding method. Due to the smaller size of the coreless coils, these coils have substantial applications in vein insertion. When the required winding number is high, for instance, 400, 600, 1000, or 2000, then it is important to reduce the thickness of the wires. However, to work with wires of smaller thickness, manufacturers require special expertise and machinery. Otherwise, the thin isolated wires can reach their isolation breakpoint and can get damaged.

Due to the substantial electric conductivity of the copper material, most manufacturers use insulated copper wires for the production of miniature coils. Nevertheless, depending on the application area and the needs of the customers, manufacturers can produce coils of different materials. The two parallel leads can result in a declined inductance. When it comes to producing highly sensitive devices, the bifilar wrapped coils are useful.

Factors to Influence the Production Process:

Several factors can influence the custom wire coil production process, such as-

  • The winding process of miniature coils requires very thin and tiny threads. The diameter of these threads can be 58 AWG to 61 AWG. These tiny wires (approximately 9 microns in diameter) are essential when there is a need to produce tiny medical devices. For example, miniature coils are essential in the case of catheterization.
  • For the production of the devices for various miniaturization applications, the designers should possess an array of capabilities for providing different types of winding services.
  • For the production of custom wire coils, various advanced methods are necessary, such as thermal compression bonding technology.

Ultra-Fine Wire Connectivity Solution:

It is not easy to connect different ultra-fine wires. Traditional soldering-based methods can result in poor conductivity, heat damage, degradation connections, isolation damage and other issues. To avoid all these issues and build an effective connection, modern manufacturers use thermal compression bonding technology.

The Applications of Custom Wire Coils:

The custom wire micro-coils have an enormous number of applications in the medical field, such as for the production of tiny implants, implant batteries, electrical charge input, pain management devices, etc. the micro-coils are also useful in RF treatments, electromagnetic pulse treatments, dental, and orthopedic treatments. Custom micro-coils are essential to produce medical sensors and treat different unapproachable areas of our body.