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Custom Coil Winding

Today, coil manufacturing requires a specialized approach to product design and development due to the unique requirements of various devices and applications, including custom coil winding.

Table of Contents

Scope of Coil Application

Nowadays, there are a huge number of devices that are equipped with coils. They are used as follows:

In invasive medical devices of different types, such as miniature implants, sensors, end devices in electrophysiological treatments and in electricity-based ablations, etc. To learn more, visit our Micro Coils for Medical Devices page
In different types of transformers ― grid transformers, current transformers, low voltage/high frequency and high voltage/high frequency transformers, chokes, etc.
In toroids for a wide range of applications , from noise reduction to filtering, including toroids
pre-installed on dedicated mounts for fast and reliable PCB assembly;
In scientific/laboratory equipment and during experiments;
In measurement instrumentation;
Upon implementing the function of induction heating;
In applications requiring electromagnetic pulses.

Considering this demand, manufacturing custom-built coils necessitates a comprehensive approach to create specific models, particularly for solutions used in medical devices, scientific activity, or precision instruments. Therefore, such work should be carried out by experienced professionals.

Coils can be differentiated primarily by shape, which can be round, rectangular, or elliptic, and they need to be built according to pre-determined specifications. Some coils are wound with cores while others are coreless. The winding can be either single-layer (ordinary or in increments), or multi-layer (double layers or more). Coils can be divided into two types based on the number of wound wires — ordinary and bifilar. Bifilar coils are wound with two parallel wires situated next to each other on the same core and isolated from each other throughout the winding.

Both the inner and external dimensions are crucial for any coil, thus maintaining precise dimensions is critical. There are coils limited to the width of 0.8 mm that have 400 windings of ultra-fine wire, down to the finest serially manufactured size of 8 microns (0.08 mm, or 60 AWG), which is 5 to 12 times thinner than a human hair. Such small coils can only be produced with our proprietary equipment, while standard machinery existing in the market can be used for manufacturing larger coils.

Best in the Field

Custom coil winding requires not only the availability of special equipment, but also the skill and knowledge of its application. Providing such services, Benatav relies on both modern machines and the best technological approach.

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

Advantages of the company as a provider of custom coil winding include:

the availability of high-notch technological equipment;
professional employees with many years of experience in the industry;
the creation of frames of various shapes;
winding coils of a unique type;
high speed order fulfillment;
quality assurance.

Benatav is engaged in manufacturing coils of various types and purposes. Our technological equipment allows us to produce high-quality, custom-made coil windings in the shortest possible time. This is why customers approach us with both unique, individual orders and serial products.

The quality assurance program is an integral part of our manufacturing process, ensuring that Benatav’s products meet the standards necessary to satisfy our customers’ demands and expectations.