Custom Coils, Inc. specializes in designing and manufacturing custom coil windings for clients across all major industries, including aerospace, medical, power generation, imaging, semiconductor, military and defense, and more. Our products include custom electromagnetic parts, assemblies, and coils. Along with manufacturing and assembly, we provide design for manufacturability (DFM), tooling, project management, and engineering services.
We build custom coil windings that align with the unique parameters of your project. Read on to learn more about our custom coil winding services.
Custom Coil Winding Services to Your Specifications
Our custom coil winding services can accommodate your exact specifications for coil type, shape, materials, production techniques, and other requirements. Our team will work with you to specify the following factors.
Coil Types
Six different coil types we produce include:
- Air core: Air core coils have a core made from air rather than a magnetic material.
- Bobbin wound: These coils are wound very precisely around a rigid core, or bobbin, which creates highly consistent and reliable windings that can produce higher inductance levels.
- Field coils: Field coils are copper wires or strips wound around a core made from laminated steel. This type of coil is commonly used in rotating electrical machines.
- RF match coils: Specifically designed for RF circuits, RF match coils optimize power transmission and are constructed from copper wire loops.
- Water-cooled coils: Rather than having a coiled wire, water-cooled coils feature conductors with hollow cores that transmit cooling fluids.
- Self-supported coils: Self-supported coils are wound with a bondable wire, so they retain their shape without a center core.
Coil Form Materials
At Custom Coils, Inc., we can construct coils from the following materials:
- Aluminum
- Copper
- Hollow core tubing
- Litz wire
Coil Winding Techniques
Two key factors shape the type of coil winding in a specific design: the winding technique and the winding process. The proprietary winding techniques we use at our in-house facility are:
- Bobbin coil winding
- Helical coil winding
- Orthocyclical coil winding
- Upset coil winding
- Sandwich coil winding
- Wild coil/random winding
Coil Winding Processes
The coil winding process is selected based on the parameters of your project. Our winding methods include the following options:
- Single-layer winding
- Multi-layer winding
- Dry/epoxy winding
- Precision winding
- Random layer winding
- Self-bonding winding
- Manual and automated winding
Coil Shape
Finally, consider the winding shape based on the requirements of your assembly. Some of the coil shapes we produce are:
- Oval
- Rectangle
- Round
- Square
- Custom three-dimensional shapes
We specialize in complex coil projects with stringent tolerance requirements.