Leading Custom Coil Manufacturers

What Is a Custom Coil?

Custom coils are made considering the form material, the wire material, the wire type, and the wire coiling process. The types of wire commonly used when making custom coils include copper and aluminum. In the process of wire production, the wire can be created using processes such as single layer, multi-layer, random layer, self-bonding, dry or epoxy wound, precision winding, and manual or automated.

The two main types of coils classified according to their function include electromagnets, transformers, transducer coils, and inductors. The inductors are also named reactors, and they are the coils that generate a magnetic field that interacts with the coil itself to induce a back electromagnetic force (EMF). Electromagnets are used to generate a magnetic field for an external purpose, often in the generation of a mechanical force onto something.

How Custom Coils Are Made

The custom winding process is used in the production of the custom coils. This process includes twisting ultra-fine wires around a contained core or pin in a round, spherical, or helical shape. However, different users may have different requirements for the shape and the size of the coils. For example, some people may require coreless coils. To manufacture these coreless coils, the manufacturer must remove the core after completing the winding process of the coils to be able to insert the coil into the vein.

Coreless coils have a great advantage since they are more effective. To produce custom coils with different thicknesses, the manufacturers change the number of windings contained around the core. These windings can be placed into classes, including single or multi-layer winding. The wires used in the production are connected, which helps ensure their protection against reaching the isolation breakpoint.

Due to its conductivity, copper is used to make most of these ultrafine wires. Different materials such as stainless steel, gold, platinum, titanium, aluminum, and titanium alloys are also used. This is because of the different applications in which custom coils are required. Ultra-fine wires are essential for preparing the custom coils, but a great challenge arises in handling them, especially in connecting two wires. This challenge can be tackled using thermal pressure bonding technology, which helps in effectively bonding these ultra-fine wires.

Types of Custom Coils

Custom coils can be grouped in relation to their wire type, area of application, wire coiling process, the shape of the coil, and the form and wire material. Coils can be grouped according to their function and the frequency of the current with which they work.

Frequency-Based Custom Coils

These coils are based on the type of current frequency they are made to work with. For example, coils may be direct current, which means that they function with a steady or direct current in their windings. Coils can also work with audio frequency, and these function with alternating currents in the audio frequency range ranked less than 20 kHz.

Function-Based Custom Coils

These types of coils include electromagnets, transducer coils, inductors, and transformers. Electromagnets are coils with a specific mandate of generating a magnetic field for external use. In contrast, inductors are used to generate a magnetic field that interacts with the coil itself to induce a back EMF.

Applications and Uses of Custom Coils

Custom coils are essential as they can be used as pain management devices and to monitor pacemakers. For electricity-based ablations, microwave and radio frequency coils are ideal. The electromagnetic custom coils are used in the dental field and other fields, including electrophysiology and orthopedic treatments.

Custom coils are also essential for the production of orientation and navigation sensors. In the medical field, custom coils can be used to produce devices such as miniature implants and medical sensors. Furthermore, the custom coils can be used in measurement instrumentation in laboratories.

Choosing the Right Custom Coil Manufacturer

For the most positive outcome when purchasing custom coils from a custom coil manufacturer, it is important to compare several manufacturers using our directory of custom coil companies. Each custom coil manufacturer has a business profile page highlighting their areas of experience and capabilities, along with a contact form to directly communicate with the manufacturer for more information or request a quote. Review each custom coil business using our proprietary website previewer for a better understanding of what each company specializes in. Then, use our simple RFQ form to contact multiple businesses with the same form.