Posted by John Quinn on | Comments Off on Best Practices for Coil Design and Materials
Designing High-Performance Coils Requires More Than Just Wire Winding
Coils play a critical role in applications ranging from medical imaging and aerospace systems to industrial automation, telecommunications, and scientific instrumentation. Whether used in RF systems, solenoids, transformers, electromagnets, or sensing devices, coil performance directly impacts efficiency, reliability, thermal stability, and overall system functionality.
At Custom Coils, every custom electromagnetic solution is engineered around the specific electrical, mechanical, and environmental requirements of the application. Successful coil design involves far more than selecting wire and winding patterns. Engineers must carefully evaluate electrical requirements, magnetic behavior, thermal conditions, mechanical stresses, and environmental factors to create a coil that performs consistently over time.
This article explores several best practices engineers should consider when designing coils and selecting materials for demanding applications.
Start with the Application Requirements
Every successful coil design begins with a clear understanding of the operating environment and system objectives. A coil intended for a high-frequency medical imaging system will require a vastly different design approach than one used in heavy industrial automation or aerospace electronics.
The engineering team at Custom Coils works closely with customers early in the development process to understand operating conditions, space limitations, electrical requirements, and long-term performance expectations before manufacturing begins.
Key considerations often include:
Electrical load requirements
Frequency range and signal behavior
Space and dimensional constraints
Thermal exposure and cooling requirements
Environmental conditions such as moisture, vibration, or chemicals
Compliance or industry-specific standards
Defining these requirements upfront allows engineers to make informed decisions regarding conductor materials, winding geometry, insulation systems, and thermal management strategies.
Selecting the Right Conductor Material
The conductor material forms the foundation of coil performance. Electrical conductivity, thermal behavior, flexibility, and durability all influence how efficiently a coil operates under load.
Copper remains the industry standard for most coil applications because of its exceptional electrical conductivity and thermal performance. Its flexibility and availability also make it highly suitable for precision winding and complex coil geometries. Copper is commonly used in applications where efficiency, consistent magnetic performance, and heat dissipation are priorities.
In applications where weight reduction is critical, aluminum may be considered as an alternative. Aerospace and portable electronic systems sometimes utilize aluminum conductors because of their lower mass and favorable conductivity-to-weight ratio.
At Custom Coils, material selection is based on the specific operational demands of each project, helping ensure the final coil design delivers the required balance of electrical performance, durability, and manufacturability.
Insulation Selection Impacts Reliability
Insulation systems are essential to long-term coil reliability. Improper insulation selection can lead to dielectric breakdown, overheating, premature wear, or electrical failure.
The ideal insulation material depends heavily on the application’s thermal and environmental demands. Polyurethane insulation is often selected for compact electronic applications because of its thin coating profile and ease of soldering. Polyimide insulation performs exceptionally well in high-temperature environments where thermal resistance and chemical durability are required.
Many industrial applications rely on polyester or polyesterimide insulation systems that provide a balanced combination of thermal endurance, durability, and cost efficiency.
Because insulation performance directly impacts operational lifespan, Custom Coils carefully evaluates temperature exposure, voltage requirements, and environmental conditions during the engineering process to help maximize long-term reliability
Optimize Winding Geometry and Coil Layout
Coil geometry has a direct impact on magnetic performance, resistance, efficiency, and manufacturability. Even small variations in winding consistency can influence inductance values, heat generation, and long-term stability.
Efficient winding layouts help minimize unnecessary wire length, which reduces resistance and lowers heat generation. Maintaining consistent winding tension is equally important, as uneven tension can create dimensional inconsistencies and mechanical stress within the coil assembly.
Engineers must also balance fill factor carefully. While maximizing conductor density can improve magnetic coupling and power density, excessive packing may restrict cooling airflow and increase thermal stress during operation.
Precision winding and repeatability are especially important in industries where performance tolerances are extremely tight. Custom Coils manufactures precision wound coils for applications that demand high levels of consistency, reliability, and electromagnetic accuracy.
Thermal Management Should Never Be Overlooked
Heat is one of the most common causes of coil degradation and failure. Excessive temperatures can damage insulation systems, alter electrical characteristics, and significantly shorten operational lifespan.
Effective thermal management begins during the design phase. Engineers should consider how the coil will dissipate heat under both continuous and peak operating conditions. Material selection, conductor sizing, airflow, encapsulation methods, and overall assembly design all contribute to thermal performance.
Common thermal management strategies include:
Optimizing conductor sizing to reduce resistive losses
Incorporating airflow or cooling pathways into assemblies
Selecting higher thermal class insulation systems
Using encapsulation or potting materials when appropriate
Designing for both continuous and peak-load operating conditions
The engineering and manufacturing teams at Custom Coils understand how thermal conditions affect long-term coil reliability and work to optimize designs for stable performance in demanding environments.
Magnetic Performance Depends on Multiple Variables
Magnetic efficiency is influenced by several interconnected design factors, including wire gauge, turn count, current levels, core materials, and operating frequency.
Core material selection is especially important. Ferrite cores are commonly used in high-frequency applications because they minimize eddy current losses and support efficient RF performance. Iron cores are often preferred in power applications where stronger magnetic fields are required at lower frequencies. Air core designs may be selected in applications where magnetic linearity or reduced interference is important.
Because these variables interact closely, electromagnetic modeling and simulation can be valuable tools during the design process. Early analysis often helps engineers optimize performance before production begins.
For highly specialized applications, Custom Coils develops custom electromagnetic solutions tailored to the electrical and magnetic performance requirements of each customer’s system.
Environmental Conditions Matter
Many coil assemblies operate in harsh or highly specialized environments. Moisture, chemicals, salt exposure, vacuum conditions, radiation, vibration, and extreme temperatures can all affect long-term reliability.
Designing for environmental durability requires careful consideration of both materials and protective measures. Epoxy encapsulation, specialized coatings, hermetic sealing, and reinforced structural supports may all be necessary depending on the application.
From aerospace systems to medical and industrial applications, Custom Coils engineers coils designed to withstand demanding operating conditions while maintaining consistent performance over time.
Design for Manufacturability
A high-performing coil must also be practical to manufacture consistently and efficiently. Designs that appear effective in theory can become difficult or costly to produce if manufacturability is not considered early.
Close collaboration between engineering and manufacturing teams can help optimize tolerances, winding methods, lead terminations, and testing requirements before production begins. Early manufacturing input often improves quality consistency while reducing lead times and production costs.
By combining engineering support with precision manufacturing capabilities, Custom Coils helps customers move efficiently from prototype development into scalable production.
Testing and Validation Remain Essential
Even the most carefully engineered coil designs require thorough validation before deployment. Testing helps confirm that the final assembly performs as expected under real-world operating conditions.
Electrical testing typically includes resistance, inductance, and dielectric evaluations. Additional validation may involve thermal cycling, vibration testing, environmental stress screening, and frequency response analysis depending on the application.
Comprehensive testing helps identify potential weaknesses early and improves long-term reliability in the field. Quality assurance and performance verification remain critical components of the manufacturing process at Custom Coils.
Final Thoughts
Effective coil design requires balancing electrical performance, thermal management, material science, manufacturability, and environmental durability. Every design decision — from conductor selection to insulation systems and winding geometry — plays a role in determining long-term reliability and system efficiency.
By following proven engineering best practices and selecting materials carefully, manufacturers and design teams can develop coils capable of meeting the demands of today’s most advanced applications.
Custom Coils provides custom-engineered electromagnetic solutions for complex industrial, aerospace, medical, defense, and scientific applications where precision and reliability are critical.
Posted by John Quinn on | Comments Off on How Magnetic Actuators Support Satellite and Aerospace Systems
The Precision Demands of Modern Aerospace
Modern aerospace systems like satellites are increasingly shifting toward electric propulsion and electromagnetic actuation. Electromagnetically powered movement systems offer a far greater degree of propulsion control, motion control, and positioning than chemically propelled systems. Unlike off-the-shelf electromagnets, custom electromagnetic components provide the optimal performance, reliability, and control necessary for mission-critical satellite applications.
Learn more about how custom-engineered electromagnetic assemblies are used in space.
Understanding the Electromagnetic Actuator in Space
Through an effect known as the Lorentz Force, an electromagnetic actuator uses a current from the magnetic field and a perpendicular force to accelerate an object through space. In this case, the electrified conductor is the propellant, in contrast to gas or liquid propulsion. The resulting helical or circular motion can be controlled by manipulating the electromagnetic field, giving ground crews precision control over the actuator.
Satellite Components: Magnetorquers for Attitude Control
Magnetorquers are a type of magnetic actuator. They interact with the magnetic field around the Earth to generate torque that satellites can use to change or maintain their orientation. Key functions of magnetorquers in attitude control include:
De-tumbling satellites after they reach the right position
Supporting three-axis stabilization in three-axis control systems
De-orbiting small satellites to prepare for re-entry
Unloading momentum from complementary control actuators
Desaturating reaction wheels
Depending on the specific satellite application, common examples of magnetorquer types include magnetic torquer coils, bars, and air core magnetorquers.
Reaction Flywheels: Fuel-Less Angular Momentum Control
Satellites can use electromagnetic actuators in reaction and momentum wheels to manage angular momentum without using chemical-based fuel, which has downstream benefits of conserving fuel and lowering the total weight of the initial launch. Flywheels use electromagnetic coils to actively control positioning for optimal Earth observation, antenna alignment, and data link quality.
Satellite Protection and Measurement
Custom electromagnetic assemblies also play a role in the satellite’s efficiency, performance, and longevity. For example, high-accuracy electromagnetic coils can operate as sensors to measure ambient magnetic fields, collect data to monitor seismic activity, make weather forecasts, and conduct other studies with greater accuracy.
Furthermore, because electromagnets weigh far less than chemical-based systems and the fuels they need to operate, satellite manufacturers can reduce construction costs, decrease the amount of shielding on the satellites, and better harness the planet’s existing magnetosphere’s shielding capabilities. By being lighter and better at harnessing existing electromagnetic forces, satellites become more efficient and reliable.
Electromagnetic propulsion systems represent a significant leap forward in fuel efficiency for modern aerospace applications. By utilizing electromagnetic actuators and high-precision coils, these systems allow satellites to achieve complex maneuvers with minimal propellant mass, significantly extending mission lifespans.
Electromagnetic actuators support high-efficiency thrusters, such as:
Hall Effect Thrusters: At the open end of the thruster, the plasma creates a negative charge. A radial magnetic field confines the electrons, while propellant is fed through an anode. As the propellant diffuses into the thruster’s channel, the confined electrons ionize it, and the resulting ions are accelerated between the cathode and anode to generate thrust.
Pulse Plasma Thrusters: An electric arc is sent through fuel to transform it into plasma, which travels between two capacitor-charged plates. This process charges the plasma, generating a powerful electromagnetic field. The resulting Lorentz Force exhausts the accelerated plasma at high velocities to create thrust.
Gridded Ion Thrusters: Negatively charged electrodes on the downstream end create an electric field that facilitates acceleration, while coaxial apertures on the electrode act as lenses to focus the ions. Upstream, positively charged electrodes serve as an accelerator grid that attracts ions to create numerous concentrated ion jets.
These applications all require electromagnetic coils that can withstand vacuum, zero gravity, and extreme temperature fluctuations. At Custom Coils, we’ve developed satellite thruster coils that provide optimal performance in space.
Why Custom Coil Engineering Is the Aerospace Differentiator
In high-stakes aerospace applications, custom coils provide the optimal performance necessary for long-term deployment. Custom Coils has over 55 years of experience creating high-performance electromagnetic components and assemblies that meet custom requirements for size, weight, power consumption, and torque in mission-critical operations.
Our designers use CAD modeling and digital simulations to streamline design, creating custom coils that prevent off-gassing in space vacuums and minimize magnetic hysteresis across wide temperature ranges. All of our products undergo robust testing protocols and come with 100% component traceability. Our facilities comply with ISO 9001:2015, ISO 13485, NEMA, and UL standards for consistent quality.
Learn More About Custom Coils’ Magnetic Actuators for Satellites and Aerospace Components
Modern satellite components rely on precision electromagnetic actuators and coils for reliable movement, positioning, and performance. Custom Coils develops magnetic actuator assemblies for aerospace and satellite component manufacturers, delivering superior propulsion and control across dozens of applications. Contact us to learn more about our custom electromagnetics capabilities, or schedule a free consultation to discuss your project.
Posted by Custom Coils on | Comments Off on How Precision Electromagnets Enable Accurate Qubit Control
Quantum computers operate on fundamentally different principles than classical systems. Unlike classical bits, which only exist in either a 0 or a 1 position, qubits can exist in a superposition state, which represents 0, 1, and all positions in between. This unique property enables quantum computers to solve complex problems far beyond the capabilities of traditional computers.
Learn more about the importance and challenges of qubit control and how precision electromagnets enable accurate qubit manipulation.
What Is Qubit Control?
Qubit control refers to the precise manipulation needed to execute a specific logic operation. For superconducting qubits like transmon or fluxonium designs, this manipulation occurs through carefully shaped flux or microwave pulses that accurately rotate the qubit’s state vector on the Bloch sphere.
Why Is Qubit Control Important?
Quantum systems perform complex calculations at extremely high speeds. However, this power requires ultra-precise qubit control. Even minor interference can disrupt a qubit’s quantum state, causing computational errors.
Understanding what validation testing means for quantum systems becomes critical here. Engineers must verify that control signals produce the intended quantum states by measuring gate fidelities, readout accuracy, and coherence times. This validates qubit performance prior to use in real-world applications.
Challenges of Qubit Control
Controlling qubits differs fundamentally from manipulating classical bits, which only toggle between 0 and 1. A qubit’s 0, 1, or superposition state demands exceptionally fine control, making quantum systems engineering one of the most challenging fields in modern physics.
These are some of the primary challenges of qubit control:
Decoherence. This refers to a qubit losing its quantum properties due to its interactions with the environment. Decoherence can quickly cause errors, limiting the available time for a given quantum computation. Thus, maintaining qubit coherence for sufficient periods is a crucial technical requirement of any qubit control system.
Quantum gate fidelity. Achieving gate fidelities above 99.9% requires exact control over the electromagnetic environment, which is why quantum computing hardware demands precision-engineered components. Without high gate fidelity, small errors in state-change operations can accumulate and cause significant computational errors.
Environmental sensitivity. Even slight temperature fluctuations, electromagnetic interference, and mechanical vibrations can degrade qubit performance.
How Do Precision Electromagnets Enable Qubit Control?
Quantum computing control hardware relies on electromagnets that may serve various functions across quantum architectures. Here are some examples of precision electromagnet applications in qubit control:
Neutral-atom and trapped-ion quantum computers rely on precision electromagnets to contain atoms within vacuum chambers, where microwaves change their quantum states.
In quantum computing control systems, electromagnetic fields and microwaves also control the movement and activity of superconducting and semiconducting qubits. The more precise and consistent the electromagnetic field, the higher the gate fidelities.
Particular qubits, such as nitrogen-vacancy centers in diamond, need the help of electromagnets to communicate with one another through magnons.
In addition to developing more advanced precision electromagnets, researchers are exploring other strategies to overcome qubit control challenges:
Quantum error correction codes. This involves encoding information across several qubits so that even if some qubits are compromised, the necessary information can still be retrieved accurately.
Superconducting materials. Operating at cryogenic temperatures, superconducting qubits demonstrate longer coherence times, reduce thermal noise, and improve overall stability.
Improved shielding. These advanced systems protect qubits from electromagnetic interference, temperature fluctuations, and cosmic rays.
Pulse shaping. These quantum control techniques are being refined to more precisely control qubits with external fields.
Applications of Qubit Control in Quantum Computing
Qubits are implemented in several types of computing hardware, each requiring specialized quantum control systems:
Neutral atom quantum computers. These trap individual atoms using laser beams or electromagnetic fields, which manipulate the neutral atoms to control the qubits.
Trapped ion quantum computers. These immobilize charged ions in vacuum chambers using electromagnetic fields, achieving high gate fidelities, long coherence times, and low error rates.
Superconducting quantum computers. These use superconducting materials and circuits cooled to near absolute zero. Electromagnets generate the precise pulses needed to control individual qubits.
Spin qubit quantum computers. These computers encode information in the spin of electrons in semiconductor materials. Precision electromagnets create the field environments necessary for long coherence times.
Custom Coils: Your Engineering Partner in Quantum Computing
Qubit control remains one of the defining challenges in quantum computing. Decoherence, gate fidelity, and environmental sensitivity all demand extreme precision from quantum computing hardware components.
Custom Coils manufactures precision electromagnetic coils for quantum computing applications. We work with quantum researchers and engineers developing hardware for trapped-ion systems, superconducting qubits, neutral-atom computers, and spin qubit platforms. Our ISO 9001:2015 certified processes support the exacting requirements of quantum systems engineering.
We provide custom design, prototyping, production, and testing capabilities for electromagnetic assemblies, driving the future of quantum computing applications. Contact us or schedule a free consultation to discuss your project requirements.
Posted by Custom Coils on | Comments Off on When to Choose Custom vs. Off-the-Shelf Coils
Every engineering choice has trade-offs. As a general rule of thumb, most off-the-shelf coil components have fast lead times, are more cost-effective, and are available from multiple sources. But custom products offer optimal performance for specialized applications and are tailored for your specific operating environment. Many critical applications, such as medical imaging and scanning, semiconductor manufacturing, and satellite production, depend on optimized design performance of their electromagnetic assemblies.
Choosing the right coil is an important decision that must consider finances, long-term product success, and competitiveness in your industry. For electromagnetic assemblies with certain application constraints, custom coils are the best option.
Main Considerations
Every production project will have unique concerns that take precedence. Here are four key factors when specifying a coil for your project.
Cost
Cost is a major consideration for every project. Off-the-shelf coils are generally most affordable upfront because they have already completed laboratory and regulatory testing for product safety and have wide availability across multiple manufacturers.
However, due to their design limitations, off-the-shelf coils in highly specialized products can lead to suboptimal performance, which can mean higher replacement costs over the product’s entire service life or even product failure. In fact, if the magnetic coil in your application is so critical that achieving less than optimal performance means product failure, then a custom coil is your only option.
Performance Requirements
Off-the-shelf coils may not align with particular design and performance needs, leading to poor or inconsistent performance and frequent replacements. If you have unique performance requirements, a custom coil manufacturer can work with you to create precision-engineered solutions that provide the right power, connections, mounting, thermal management, and mechanical properties within the given space constraints.
Operating Environment
Different electromagnetic assemblies are intended for different environments, each with its own potential hazards that can shorten the functional lifespan of a coil. Off-the-shelf coils can be designed for particular uses, but custom coils better serve highly specific, regulated applications with harsh operating environments, such as extreme cold or heat, radiofrequency interference (RFI), and more.
Lead Time
Since off-the-shelf coils don’t have prototyping and testing periods, their lead times are much faster than custom coils. However, if you partner with an experienced custom coils provider, they can streamline these processes as much as possible while delivering a coil that’s a perfect fit for your application.
When to Choose Custom Over Off-the-Shelf Coils
Custom coils should be chosen instead of off-the-shelf coils in these situations:
When off-the-shelf coils don’t meet your application parameters
When the magnetic component in your application is so critical that achieving optimal performance makes the difference between failure and success
When your products need to handle critical operations, such as environmental extremes
How to Find a Quality Custom Manufacturer
It’s important to choose a high-quality custom manufacturer that offers full-service operations from design to prototyping to production.
Design and Engineering
Your custom coil manufacturer should specialize in coil design and engineering, including design for manufacturability (DFM) analysis. Custom Coils provides design support and engineering expertise to create designs that exactly align with project parameters and tight tolerances.
Prototyping and Development
Prototyping and small-run production are critical stages in developing a high-performance custom coil. We provide small-batch manufacturing, prototyping, and testing for thorough R&D before large-scale production.
Manufacturing and Production
Once your designs are finalized, they should move smoothly to full-scale production. Custom Coils offers reliable, precise manufacturing at any scale. We comply with ISO, MIL-SPEC, aerospace, and medical standards so your final products meet the needs of critical industries. We also guarantee on-time delivery with every production order.
Partner with Custom Coils
If your application requires custom mechanical and electrical characteristics, Custom Coils provides complete product development. We work closely with you to design the most effective electromagnetic assemblies that function optimally in your operating conditions and offer maximum output. As specialists in custom coils, we can streamline the quality testing process given our experience and archive of test protocols from past projects. From initial design to prototyping to manufacturing, Custom Coils can handle your project from start to finish.
Contact us today to learn more about our custom coil manufacturing capabilities. Request a quote to start your electromagnetic assembly project.
Posted by John Quinn on | Comments Off on How Electromagnets Are Used in the Medical Industry
In contrast to permanent magnets, which always have a magnetic field, electromagnets only create a magnetic field when electricity runs through them. They are made from coiled wire, often wrapped around a core of ferromagnetic material, such as iron, or a coil with a hollow core (i.e., air core). The coil is connected to a power source, which gives the ability to create the magnetic field, power it down, and manipulate it in precise ways. This has opened the door to advanced medical imaging, instrumentation, and therapy applications.
But to provide these advanced capabilities, the electromagnets need to meet quality standards, such as ISO 13485, and other patient safety requirements. Here, we’ll look at some popular applications of medical electromagnets for diagnostics, therapies, and other tasks.
Diagnostic Equipment (Imaging & Scanning)
Electromagnets are widely used in diagnostic imaging and scanning systems such as MRIs and MPIs.
MRI Machines
MRI machines use superconducting solenoid electromagnet coil systems and smaller gradient coils that align hydrogen protons in a patient’s body. Radiofrequency (RF) coils work alongside these systems to transmit and receive signals. Together, they can generate responsive signals in a patient’s body and detect those signals, which machinery then translates into images.
Magnetic Particle Imaging (MPI)
This developing technology uses multiple electromagnets. A patient is given an injection of iron-oxide tracer nanoparticles, and the electromagnetic coils excite the particles, forcing them to emit signals that sensors can detect and transmit.
MPIs directly create incredibly detailed images that diagnosticians can use to examine their patients.
Other Diagnostic Uses
Other advanced imaging systems include MR spectroscopy for analyzing chemicals in tissue and Xenon MRI for advanced lung imaging.
Therapeutic Technologies
Electromagnetics are used in many advanced therapy and treatment protocols.
Radiation Therapy (Linear Accelerators)
Modern radiotherapy systems use advanced electromagnets to direct and focus particle beams at tumors. They use linear accelerators with custom-wound solenoids or C-core electromagnets for high-precision results.
Targeted Drug Delivery
Researchers have developed methods for harnessing magnetic nanoparticles (MNPs) to deliver doses of medicine within the bloodstream. High-precision electromagnets are used first to direct the nanoparticles to exactly the right site, such as a tumor, and then to trigger the release of the medication. This process delivers high-concentration pharmaceuticals with minimal impact on nearby tissue.
Magnetic Hyperthermia
With this emergency cancer treatment, magnetic nanoparticles are sent to a tumor using electromagnetically powered direction. Then a separate electromagnetic field causes the particles to heat up to around 45° C, killing cancer cells without destroying healthy tissue.
Neuromodulation (Transcranial Magnetic Stimulation (TMS)
In TMS, high-precision electromagnets placed on the patient’s scalp activate to produce short magnetic pulses that stimulate the brain. This non-invasive procedure can help with depression and other neurological conditions.
Surgical and Procedural Tools
Many innovative medical tools and instruments use specialty coil electromagnets. These help with precision guidance and control during surgery and other procedures.
Magnetic Surgical Robots and Devices. Magnetically actuated robotics are controlled with external magnetic fields to assist with surgery.
Magnetically Steerable Catheters and Guidewires. Catheters or guidewires with a magnetic tip can be directed by an electromagnetic field, allowing for safe, fast, and highly controlled movement for stroke interventions and cardiovascular treatments.
Other Magnetic Tools. Other applications for electromagnets include magnetic anchors that hold surgical tools in place, steering mechanisms for wireless endoscopes, and locking retractors.
Research Frontiers in Electromagnetics & Medicine
Scientists and researchers continue to explore new applications for electromagnetics in advanced medical settings. Consider these future possibilities:
Advanced Imaging (MPI and Beyond). MPI machines directly produce real-time images, replacing X-rays and allowing for incredibly detailed images. These machines will continue to improve over time.
Xenon MRI. Xenon MRI systems interact with hyperpolarized xenon gas to produce alveolar-level images and create more diagnostically helpful insights.
Magnetic Micro/Nanorobots. Robots are getting smaller, and developers are working on making microscale robots for in-body drug delivery, microsurgery, blockage removal, and other minimally invasive procedures.
Theranostics (Combined Therapy+Diagnostics). Theranostic nanoparticles can be used as contrast agents in MRI and MPI scanning or to provide hyperthermia or drug delivery treatments.
Magnetogenetics and Neuromodulation. Magnetic fields may be able to one day control and correct cellular activity deep within tissue, even in the brain. They may also provide wireless magnetic power for medical implants.
Looking Ahead: The Future of Electromagnets in Medicine
Electromagnets can drive increasingly advanced medical interventions and therapies, and function as powerful diagnostic tools. As coil designs evolve, the potential for new applications will continue to grow across virtually all fields of medicine.
At Custom Coils, we’re committed to driving the science of electromagnetics and coils forward to unlock greater medical advancements. We provide high-quality electromagnets for state-of-the-art medical applications and have decades of experience developing RF coils, inductors, solenoids, and more.
Contact us today to learn about partnering with us on custom-engineered electromagnet solutions, or request a quote to start your project.
Posted by John Quinn on | Comments Off on Solenoids: Working Principle, Types, & Applications
Click to Expand
A solenoid is a type of electromagnet consisting of coiled copper wire wound tightly into a helix, a mobile plunger made of magnetic material, and an iron or steel housing. As electric current moves through a coil, the solenoid generates a magnetic field and proceeds to transform magnetic energy into mechanical motion. It does this through electromagnetic forces.
For example, solenoids are often used as a valve to actuate a push or pull force on a magnetic component in a device. Solenoids can also act as a switch in electromechanical devices. These electromagnetic devices are used in hundreds of everyday applications, from doorbells to car ignition systems.
Custom Coils designs and develops quality solenoids to meet the needs of your application. We work efficiently and expertly to create specialty coils for our valued customers.
How Does a Solenoid Work?
When an electric current is applied to a solenoid, it creates a powerful magnetic field that attracts or repels a magnetic material (i.e., a magnetic plunger) to move inside its housing. As the plunger moves back and forth, it creates the mechanical motion that powers the intended component.
Within a long solenoid, this magnetic field is uniform and strong. It is similar to what you would see with bar magnets. It combines field lines, positioned parallel with the coil’s inside, and fringe fields, which are external and weaker in strength. You can increase a solenoid’s strength by incorporating an iron core.
The ideal solenoid’s magnetic flux density, B, is represented by the following formula: B=μ·LN·I.
μ/mu_μ: Free space permeability
N/LN/LN/L: Turn density, or the number of turns per unit length
I: Current
Given the behavior of the field, solenoids are typically utilized in applications requiring a controlled magnetic field.
Solenoid magnets have an advantage over conventional permanent magnets because their magnetism can be switched on or off — or altered — as needed by removing or applying varying levels of electrical current. You can adjust the strength of the magnetic pull by increasing or decreasing the electrical current. Additionally, you can reverse the direction of motion based on the direction of current flow through the solenoid.
There are two basic types of solenoids: valve and electric. In valve solenoids, a constant electric current is applied to the solenoid. Once activated, the piston or plunger retracts to open the valve that would otherwise block the flow of material. Once the electromagnetic field is broken, the solenoid is deactivated and the valve will close.
Electric solenoids close circuits to allow engines to run. When the solenoid receives the electric current, it pulls nearby metal components in place to create a closed circuit. Constant electric current is required to keep the circuit closed and the engine running.
Types of Solenoids
Numerous solenoid types are available to suit the needs of diverse applications. These types include:
AC-laminated solenoid: This solenoid comprises a wire coil and a metal core made with laminated metal, which helps reduce stray currents and optimizes the solenoid’s performance. An AC-laminated solenoid has an inrush current, which delivers a greater amount of force in the initial stroke. This also means it can deliver more strokes than DC-laminated solenoids. Common applications of an AC-laminated solenoid include locks, medical devices, industrial equipment, vehicles, and other equipment that needs immediate operation.
DC C-frame solenoid: Some applications may also use a DC C-frame solenoid, which features a C-shaped frame that wraps around the wire coil. Suitable for many everyday applications ranging from gaming equipment and coin counters to scanners, camera shutters, and circuit breakers, this solenoid utilizes a stroke operation with excellent control. While it has a DC configuration, a solenoid of this type is actually AC power equipment compatible.
DC D-frame solenoid: Like C-frame solenoids, the DC D-frame solenoid operates with more controlled strokes and is compatible with AC power applications. The main difference is that the D-shaped frame is made with two joined pieces that shield the coil. ATMs, gaming machines, and gas- and blood-analyzing equipment often use this solenoid type.
Linear solenoid: This is one of the most widely recognized solenoids. A linear solenoid features a coil-wrapped metal core, delivering pushing or pulling force to operate a piece of equipment. This operation makes it popular for vehicle ignition systems and other such starting devices, as well as electric locks that allow locked vehicle doors to withstand significant force.
Rotary solenoid: If an application needs a simple automatic control process, it may use a rotary solenoid, which has the same essential components as other solenoids but with a unique mode of operation. A rotary solenoid uses a metal core located on a grooved disc to function. The size of the grooves is based on slots on the body of the rotary solenoid, and ball bearings facilitate and streamline motion. When it is powered on, the core draws back within the body while the disc core turns. When turned off, a spring forces the disc core into its original position. A more robust solenoid variety, the rotary solenoid has common applications in industrial tasks like automated lasers and shutters.
Latching solenoid: This solenoid type features a permanent magnet as well as a spring or related component to enable return force. Using just a brief excitation pulse, the latching solenoid will alter its end position. In the holding condition, it exhibits zero power or heat dissipation, so it is a good choice for temperature-sensitive applications. It is also compatible with systems that have minimal supply power because, at either end position, there is no power consumption. A latching solenoid is not, however, a good option for failsafe applications should a power failure occur.
Proportional solenoid: A type of advanced linear actuator, a proportional solenoid generates force that is proportionate to the amount of excitation current an application applies. This solenoid can, when a return spring is included in its construction, serve as a positioning device. Generally, it is utilized for position, flow control, tension, and force, and the proportional solenoid has common applications in hydraulic control systems, robotic systems, textile systems, and valves.
Applications for Solenoids
Without realizing it, you use solenoids every day. Solenoids vary in size and power, making them suitable for countless applications. Powerful solenoids consist of many coils, create strong magnetic fields, and can power large machinery. You can use a smaller, less powerful solenoid for smaller functions like ringing a doorbell. Some of the more common applications for solenoids include:
Mechanical or fluid control valves
Starting a car
Door locking mechanisms
Nail guns
Air conditioning controls inside vehicles
Powering signal systems in the railroad industry
While these simple but effective devices are used to actuate many common devices, they have become highly utilized in nontraditional physical motion applications, such as Ion Beam Accelerator systems. There are innumerable applications for solenoids, as any device that requires force to create mechanical movement can benefit from their functionality.
Solenoids in Automotive Systems
In automotive systems, the primary function of a solenoid is to carry electrical current from a car battery to the ignition system, as discussed. Typically, vehicles will have mounted solenoids on the starter motor or related starter components. Others might have them installed in another location within the engine compartment. Automotive manufacturers will often use latching or proportional solenoids, as two examples, for internal combustion engine and electric vehicle systems. Solenoid valves, additionally, play a role in fuel injection, transmission, and emission control systems.
Solenoids in Industrial Automation & Robotics
Within the industrial automation and robotics fields, solenoid-powered valves assist users in managing simple to complex pneumatic and hydraulic fluid flow within a system or piece of machinery. For example, they’re applicable for process control systems, conveyance systems, and equipment like actuators and robotic arms, in which they control actuator movement with great precision. Essentially, solenoids promote efficiency, dependability, safety, heightened speed, and overall operational improvements.
Solenoids in Medical Devices
Rotary and linear solenoids are good options for medical device applications. In equipment for medication dosing, dialysis, and monitoring blood pressure, these solenoids enable a high degree of force and stroke accuracy and reliability. This better allows medical devices to meet strict quality and safety standards within the healthcare industry while enhancing the lifespan of the equipment. Solenoid valves also play a part in anesthesia and oxygen therapy machinery, helping to automate critical medical processes and minimize the need for manual intervention.
Solenoids in Aerospace
Resulting in mechanical motion, solenoids have significant applications within the aerospace industry. They’re an important part of propulsion, release, and landing gear mechanisms as well as air- and spacecraft systems for flight control, power distribution, life support, fuel management, payload deployment, and optimal maneuverability. In satellites, solenoids are advantageous for attitude control systems, ensuring stability and precise orientation adjustment, and thermal management systems, facilitating temperature regulation and heat dissipation.
Custom Coils, Inc. Is Your Expert Partner for Solenoid Design & Manufacturing
Solenoids are important devices in much of the technology we use daily. These devices are effective, versatile, and easy to implement in your systems. From conception to production, the experts at Custom Coils will partner with you to determine your specific needs and customize the right solenoid device for your application. Contact us to learn more about our services, or request a quote today.
Posted by John Quinn on | Comments Off on Magnetorquers for Satellite Attitude Control
Emergency communications, navigation systems, the internet, and many other modern conveniences are only possible through satellite technology. As our world grows more interconnected via satellite, manufacturers must build satellites that provide reliable, long-term performance. Devices like magnetic torquers, or magnetorquers, provide high-quality attitude control and proper orientation of the satellite by interacting with the Earth’s magnetic field.
Learn more about the role of magnetorquers in satellite attitude control, how they work, and their applications.
Satellite Attitude Control: An Overview
Satellite positioning plays a critical role in each satellite’s ability to receive, collect, and transmit data. This is why satellites must continuously maintain exactly the right position and orientation while in orbit. Some of the key ways that satellite attitude control manages orientation are:
Positioning for different applications. Satellites need different orientations based on function. Earth observation satellites need a specific camera orientation, and communication satellites need their antennae at the right angle for maximum signal quality.
Protection against disturbances. Atmospheric drag, solar radiation pressure, and other external forces can make satellites rotate. Satellite attitude control systems can correct those effects.
Stabilizing. The satellite’s center of gravity can cause misalignment, and attitude control can correct bias.
Ultimately, satellite control solutions can help guarantee the success of the long-term mission by correcting misalignment over time. When designing these solutions, engineers need to consider limitations like the allowed weight, size, and energy consumption. Satellites may use a combination of different solutions ranging from control momentum gyroscopes to thrusts to reaction wheels, each of which has its benefits and tradeoffs. Magnetic torquers are a simpler, longer-lasting option with fewer points of failure.
What Are Magnetorquers and How Do They Work?
Magnetorquers have a magnetic coil or rod that generates a magnetic field whenever an electric current flows through the device. The field interacts with the Earth’s magnetic field, generating torque forces that move the satellite. Properly harnessed magnetorquers can generate the right torque to readjust satellites and move them back into alignment based on their core functions. Operating systems can control the magnetic field and the resulting movement by modifying the direction and magnitude of the electric current.
Depending on your satellite’s unique constraints and applications, different types of magnetorquers can provide optimal attitude control. The three most common types of magnetorquers are magnetic torquer bars, magnetic coils, and air core magnetorquers.
Magnetorquer Applications
Magnetorquers provide attitude control in satellites, CubeSats, backup systems, and orbit maneuvers, performing the following main functions:
Three-axis stabilization in three-axis control systems
De-tumbling after initial positioning
Deorbiting small satellites for re-entry
Desaturating reaction wheels
Unloading momentum from complementary control actuators
Get in Touch With Magnetorquer Experts at Custom Coils
Magnetorquers offer simpler and more streamlined control over satellite positioning and realignment. Engineers can install them as a primary satellite attitude control system or in conjunction with other options like reaction wheels. These versatile devices can generate finely attuned magnetic fields to reposition satellites, neutralize disturbances, and keep satellites on track. They’re also less resource-intensive and vulnerable to failure than other solutions.
At Custom Coils, Inc., we specialize in crafting custom state-of-the-art electromagnetic solutions and coils for major industries, including aerospace companies. Our expertise in satellite attitude control systems gives our clients more options for fine-tuned control and efficient assemblies.
Contact us today for assistance choosing the right magnetorquer for your satellites, or request a quote to start your project.
Posted by John Quinn on | Comments Off on RF Inductor Basics
Radiofrequency (RF) inductors are critical electronic components in applications from consumer products to complex scientific equipment. RF inductors perform numerous functions in high-frequency circuit applications, such as high-frequency chokes, filtering, impedance matching, and circuit tuning. These inductors are prevalent in modern technology, including IoT devices, wireless devices like tablets, and specialized applications such as testing equipment and GPS.
What Is an RF Inductor?
RF inductors are passive components that oppose sudden variations in electrical currents. Sometimes called chokes or coils, inductors are symbolized by an L on electrical documentation. When an electrical current flows through an RF inductor, the energy is stored in an electromagnetic field. Ideal for high-frequency electrical applications, RF inductors provide the following functions:
Impedance of Current Changes: An inductor installed inline or in series with a circuit board trace or wire impedes current changes, like AC noise, by storing the energy temporarily in its magnetic field before re-releasing it into the circuit.
Energy Storage and Voltage Creation: As the current traveling through the RF inductor varies over time, the energy in the inductor’s magnetic field produces an opposing voltage to impede the current from changing further.
Opposing Current Changes: The magnetic field slows the rate of change as the current passes through the inductor, regardless of whether it is decreasing or increasing. RF inductors work like shock absorbers dampening mechanical energy, dispersing electrical energy spikes or current noise that would otherwise damage the system.
Characteristics of RF Inductors
RF inductors work like other inductors, governed by the same rules of physics as power inductors. They are characterized in the same terms, with parameters like inductance, permeability, and turns. These similarities allow RF inductors to use the same formulas as conventional power inductors. RF inductors also share similar parameter ranges in their datasheets, including those for rated current, DC resistance, inductance, and tolerance.
However, RF inductors also have a quality factor that is crucial to validating the inductor for performance in a specific application. Here is an overview of all the basic parameters to consider when selecting or specifying an RF inductor:
Inductance Value and Tolerance: Inductance is the most important parameter of RF inductors. Similar to conventional power inductors, it is defined by the core’s relative permeability, the core’s cross-section, the core’s effective magnetic path length, and the number of turns around the core. RF inductors require a design with high inductance stability, flat inductance curves, and tight tolerances. Tight tolerances ensure the inductance value is as close to the nominal value as possible for impedance-matching applications, oscillator circuits, and high-order filters.
Self-Resonant Frequency (SRF): Constant inductance at the relevant frequency range is vital in impedance-matching and filter applications, meaning the inductor’s SRF must be well above the circuit’s operating frequency.
Quality Factor (Q): The inductor quality factor, or Q factor, is the ratio between reactance (XL) and losses (RS) and can indicate the ideal performance of an inductor for an application. Inductors with high Q offer low dissipation and can make finely tuned narrow-band circuits. Low Q inductors offer wideband performance with higher dissipation.
RF Inductors From Custom Coils
RF inductors are electrical components that impede and control currents flowing through them by storing the energy in an electromagnetic field, releasing the current at a controlled rate, and reducing noise. In RF inductor selection, many factors are identical to conventional power inductors. However, engineers also must review the quality factor of the RF inductor to verify if it is a good fit for their application. Custom Coils can help you select the ideal RF inductor for your application with our design and manufacturing experience.
Custom Coils has manufactured chokes and inductors for various applications since 1978. Our facility is ISO 9001:2015 and ISO 13485:2016 certified to ensure quality processes and products. We specialize in designing and manufacturing custom coils for thermal and high-power applications. Our full production cycle services include developing prototypes, small- to large-volume production, testing, and more.
Posted by John Quinn on | Comments Off on Semiconductor Wafer Fabrication Process
Semiconductors are vital components in everyday life, powering cars, mobile phones, computers, TVs, and even credit cards. Semiconductor manufacturing is complex, requiring many steps and precisely controlled processes. This blog will shed light on wafer fabrication, the first step of semiconductor manufacturing.
What Is a Semiconductor Wafer?
Semiconductors serve as substrates for building microelectronic devices that control the flow of electric current. A semiconductor wafer is a thin slice of semiconductor material used in electronics for manufacturing microchips, integrated circuits (ICs), photovoltaics, solar cells, and other semiconductor devices. Substrate wafers are essential components of modern electronic devices like computer chips, smartphones, and cameras.
Semiconductor wafers are typically made from very pure single-crystal silicon or other semiconductor materials like:
Germanium
Silicon germanium (SiGe)
Gallium arsenide (GaAs)
Sapphire (Al2O3)
Indium phosphide (InP)
Silicon carbide (SiC)
Zinc oxide (ZnO)
Gallium nitride (GaN)
Diamond
Semiconductor wafer diameters range from 25.4 mm to 450 mm, and thickness varies based on mechanical strength and material properties. Wafers smaller than 200 mm in diameter typically have flats to indicate crystallographic planes, and wafers 200 mm or larger use a small notch for orientation.
Semiconductor Wafer Fabrication Process
Making a semiconductor wafer is a complex process that requires operators to follow strict standards with high precision. The following steps describe the process of semiconductor wafer fabrication.
Creating an Ingot: After silicon is extracted from sand, it is purified using a heating and refining process. The purified silicon is then melted into a high-purity liquid and solidified through crystallization to form a silicon ingot. Only ultra-high purity ingots are fit for semiconductor use.
Slicing the Ingots into Thin Wafers: Operators use sharp diamond saw blades to slice the ingots into thin wafer discs. The diameter of the ingot determines the wafer’s size. Thinner wafers lower manufacturing costs, and larger wafers increase the number of semiconductor chips produced per wafer. As a result, wafers are trending thinner and larger.
Grinding: Surface grinding corrects issues like waviness from wire sawing. The grinding process produces high-quality wafers and can sometimes replace rough polishing and lapping.
Rounding: A diamond disk smooths the edges of sawn wafers to remove damage and ensure the wafer is the required diameter.
Lapping: Wafers then go through lapping, a mechanical process using pads and slurry to flatten and polish. This step removes excess silicon and surface damage to give the wafer a dull grey, semi-reflective finish.
Polishing: Polishing gives the wafers a mirror-like finish and helps prevent breakage and warping. The process also makes them thinner and more flexible.
Cleaning: Various cleaning methods—including pre-diffusion, RCA, mega sonic, and ozone cleaning—are used to remove contamination from the wafer due to air exposure.
Patterning: The cleaned wafer is then patterned in a process called photolithography. A light-sensitive layer, or photoresist, is applied to the wafer, followed by a mask on top of the wafer. This mask contains a pattern that corresponds to the required electronic component to be produced. The wafer is then exposed to UV light, which transfers the pattern from the mask to the photoresist.
Doping: Through ion implantation, certain impurities are added to the wafer to change its electrical properties. Boron and phosphorus are commonly used to create p-type and n-type semiconductors.
Deposition: Thin films of material are deposited onto the wafer to create the desired electronic components. Various techniques for deposition include physical vapor deposition, chemical vapor deposition, and atomic layer deposition.
Etching: Plasma etching, wet etching, or dry etching removes specific parts of the wafer, shaping it according to the intended electronic component.
Inspection: By comparing photos of different dies, specialized tools inspect the wafers for defects. The most common technologies used for inspection include electron-beam inspection and brightfield inspection.
Need Coils for Semiconductor Wafer Fabrication?
The semiconductor wafer fabrication process depends on highly precise, controlled RF and electromagnetic coils. During deposition, doping, and etching, magnetic coils generate the necessary electromagnetic fields of different sizes, strengths, and consistencies to give the semiconductor wafers different properties.
Custom Coils specializes in designing, engineering, and manufacturing coils for semiconductor manufacturing, such as electromagnets for dielectric and polysilicon etching. Contact us to get started on your semiconductor wafer fabrication project today.
Posted by John Quinn on | Comments Off on The Basics of Coil Winding
Coil winding involves wrapping a wire around a cylindrical object in a spiral-like shape to produce a standalone coil or a coil on a toroid, bobbin, or other type of center support. The coil may be made of one or more layers of wires depending on its intended application.
The following factors influence the type of coil winding used in an application:
Dimensions, shape, and geometry of the coil design
Inductance properties
Insulation strength
Magnetic field requirements
Available space
Specific location of the coil in the device or system
Due to these factors, coil winding is a complex art and science. Learn more about the basics of coil winding and the different types of coil winding techniques.
Coil Winding: Basics and Machinery
An electric coil is an electrical conductor with a series of conductive wires wrapped around a core. Found in electric generators, motors, electromagnets, and inductors, electric coils provide a reliable, consistent method of inductance, effectively opposing a current’s flow.
Utilizing different types of coil winding techniques allows engineers to create single or multiple-layer coils for electronic components that meet voltage, electrical current, and heat insulation requirements.
Manual and automated winding systems are commonly used in the production of coils. The factors which influence which option is utilized includes specific design parameters and volume requirements.
As manual methods have evolved into automated processes, coil winding machinery offers enhanced precision, efficiency, and quality, benefiting most applications and industries.
Diverse Coil Winding Techniques
Engineers select the appropriate method of coil winding based on space availability, coil location, and other design specifications. Each technique offers a unique set of features and characteristics.
Wild Coil Winding
Wild coil winding is a quick and easy method that wraps the wire unevenly in a cross-winding pattern. The random wire placement results in a wider range of electric coil resistances and a wider distribution of wire lengths on the coil’s body. This type of coil winding is commonly used in high-volume mass production and is best suited for the following applications:
Devices with small wire gauges
Ignition coils
Relay coils
Small electric motors
Small transformers
Helical Coil Winding
In helical coil winding, the wire is uniformly wound in layers around a cone or cylinder to create a three-dimensional spiral shape. Each layer contains wires wound in the direction of movement, alternating between right-hand and left-hand, with each layer of wire resting in the gaps of the underlying layer. Helical coil winding is used in low-voltage windings and can include several strands or up to a hundred continuously parallel wires.
Orthocyclical Coil Winding
Orthocyclic winding is an efficient method that allows each layer of wire to fit into the grooves of the layer beneath it. Its high fill factor of 90% creates a strong magnetic field. This winding pattern allows for maximum usage of space and continues over each layer. Every turn occurs parallel to the next, with only a fractional shift between each layer.
Sandwich Coil Winding
Sandwich coil winding is a unique layered design where high-voltage windings are sandwiched between two low-voltage layers to reduce leakage flux. This type of coil winding is primarily used in transformer production and looks like a series of discs.
Bobbin Coil Winding
A bobbin coil consists of wire wrapped around a bobbin, which will vary based on current and voltage levels, operating frequency, and rating. Bobbin coils are often used in power conversion units and switch-mode power supplies, as well as many other applications.
Contact Custom Coils, Inc. for All Your Coil Winding Needs
Automated and manual winding machinery and various types of coil-winding techniques play a critical role in the performance of the intended electrical device. At Custom Coils, Inc., we have the knowledge and expertise to perform the method that best suits the demands of your specific application.
Contact us or request a quote to learn more about coil winding and how Custom Coils can serve your needs.
