Coil Winding Technology: Micro Coil Manufacturing Materials

The use of ultra-fine wires for the manufacturing of inductive components and providing connectivity within miniature medical devices necessitates the interplay of innovative coil winding technologies. These technologies hinge on a variety of methods for handling copper and other metal wires of any diameter, down to the finest serially manufactured size of 8 microns (0.008 mm, or 60 AWG)—often 5 to 12 times thinner than a human hair.

The parameters specified for coils generally depend on the application area. One of the primary parameters a designer specifies is the material to be used for the coil. Benatav manufactures custom-made micro coils from a broad array of materials, including but not limited to copper, stainless steel, aluminum, titanium, and high-purity precious metals. Careful consideration is given to the metal selection to ensure that each micro coil is manufactured to excellence.

To learn more about coil winding technology, read our White Paper.

The unique characteristics of the most common coil manufacturing materials used in the coil winding technology:

• Copper. Copper is the second most conductive material in the world after silver and due to its excellent physical properties copper wire is widely used in the medical industry. One of the primary benefits is that copper is an extremely reliable and durable material. Copper alloys are also widely popular.

Often copper wire has some sort of coating (enamelled wire). The type of coating depends on where the copper wire will be used.

• Stainless steel. Stainless steel is heat and corrosion-resistant, lightweight yet strong, durable, and fully recyclable. Stainless steel coils, ideal for potentially corrosive environments, are used for heating purposes, e.g., in the cryotherapy treatment of cancer tumors for defrosting between freezings.

• Aluminum. Aluminum coils are used to reduce weight when a portable medical apparatus gets too heavy due to a larger number of turns. High cost of manufacturing and coating makes them rather expensive and thus reduces their usage.
• High purity precious metals, such as gold and platinum. Highly conductive and chemically resistant, they are used when there is a need to come into direct contact with skin/tissue and biocompatibility of the medical device materials is required by FDA regulations. Extremely high cost makes their application very rare; however, in some cases, it is vital to use a golden or platinum thread, especially when it goes about reducing resistance.
• Titanium and titanium alloys. Titanium provides remarkable corrosion resistance. This, along with its non-magnetic properties (compared to other ferromagnetic materials), light weight and one of the highest metal strength-to-weight ratios, makes titanium ideal for many medical and dental applications.

No matter what your project requires, Benatav has the capabilities and the experience to manufacture coil products that match your exact specifications. We will also help you select the ideal material for your design. Whether you need copper coils, stainless steel coils, or any special material or design, we can create it with perfect precision and unparalleled quality within budget costs.