Coil Winding Services

Benatav offers complete coil winding services. We specialize in producing miniature coils and their assembly lines. We deal with everything required: from the castings, soldering, wrapping, gluing, etc. including the special equipment and tools needed to deliver a finished product. 

• Benatav has the required expertise to manufacture miniature coils for different industries. 
• Quality is paramount and our coil winding services are manufactured according to your needs.

Induction coils are produced by winding isolated wires. Many factors affect the coil during the manufacturing process. 

• We are experts in winding miniature coils that require very thin threads. In general, we work with threads ranging from 58 AWG – 61 AWG. Currently, the thinnest isolated thread is 8 microns and Benatav has produced coils that are only 0.8 mm wide (an industry record). Such miniature coils are ideal for medical devices such as catheterization, where size is critical.
• Benatav’s micro coil winding services offer device designers a vast array of capabilities, opening the door for endless miniaturization applications.
• Benatav has the expertise to provide all your micro coil winding services. Whatever your design requirements, we have the expertise needed to create your custom coils and devices in-house, using the necessary manufacturing techniques including our patented “Thermo Pressure Bonding”.

How is a coil made?

Coils are created by winding isolated wires around a core, and in some cases, the cores are subsequently removed, resulting in coreless coils. Generally, coreless coils are smaller and commonly used in procedures such as vein insertion. As the number of windings increases to 400, 600, 1000, or 2000, the wire thickness needs to be significantly reduced. Working with very thin isolated threads requires expertise and special machinery to prevent wire isolation breakpoints, and Benatav possesses the knowledge and experience to handle such delicate wires.

• Most coils are made from insulated copper because copper conducts electricity so well. It’s also possible to make coils from other metals depending on your application. 
• Some coils are Bifilar, two strands of the wire that are twisted and wound together. The result is that the two leads are parallel which reduces the inductance. A device requiring higher sensitivity and more efficient fill factor might require the use of a bifilar wrapped coil.

How do coils differ?

Basically, coils differ depending on the materials they are made from as well as their shape and size. 

• Generally, coils are made from copper but they can also be made from aluminum, gold, titanium, silver or any other conductive metal.
• The coil size and shape depends on its specific application/procedure.
• Certain coils need to be very small. In general, the narrower the coil, the more expensive it is.

Size matters

At present, Benatav has successfully created a coil with 400 windings that is only 0.8 mm wide, and we continue to explore the possibility of working with even thinner isolated threads if specific applications demand it.

Connecting to coils in no simple business

Connecting ultra-fine wires of a coil to terminals or wires of similar or smaller thickness is no simple task. Conventional heat-based soldering or laser micro soldering of ultra-fine wires can lead to issues such as oxidation, poor conductivity, heat damage, degraded connections, and insulation damage. In response, Benatav has developed a patented Thermo Pressure Bonding technology that enables the connection of ultra-fine wires, regardless of diameter, to other wires that are either similar in diameter or up to 12 times as thick.

For instance, if a terminal-based connection is required, the wires can be connected to a gold-plated terminal. The molecular connections formed through Thermo-Pressure Bonding deliver highly reliable, corrosion-free, and strain-free connectivity without the need for soldering, resulting in simplified manufacturing and lower costs.

Micro-coil manufacturing

Micro coils are miniature and require the use of special equipment to make them. Benatav provides complete miniature manufacturing line services for micro-coil windings, resulting in endless options and capabilities for miniaturizing applications.

In the medical field, micro coils are always custom-designed according to specifications. Common uses of medical coils include:

• Transferring control, monitoring and logging data to and from miniature implants.
• Wirelessly charging implant batteries within the body.
• Providing electrical charge input for activating and operating implants and their systems.
• Radiate energy for RF treatments, heat treatments, or electromagnetic radiation-based treatments.
• In-vivo magnetic navigation, employing a local or external magnetic field.
• Finding locations inside or outside of the body via sensors (made from 3 coils).
• Electromagnetic pulser treatments to expedite tissue fusion.

Anything inserted into the body must be medical grade. Medical grade means that the device has been manufactured according to the standards required by the medical industry such as material traceability, quality control, etc. 

Benatav possesses the expertise to custom manufacture different devices, such as pressure sensors for accurate and stable measurements of critical pressure levels in gases and liquids within the body. Combining pressure measuring devices with sensors leads to more precise diagnoses and improved treatment plans for patients. Disposable pressure sensors based on MEMS technology can be used internally or in-line with fluids entering the body.

Let Benatav know what your micro coils needs are, and we’ll find a way to manufacture it.