A micro coil winding specialist organization that has supremacy in winding coils, provides a complete package of services related to the coil winding that ranges from preparing micro coils to accumulate all assembly lines. There are many stages of coil winding such as soldering, casting, gluing, wrapping, etc and to process all these steps, the tools, and other equipment are also needed to be prepared in-house.
There are many factors related to the manufacturing process of micro coil winding. Below we have provided brief details of them in bullets:
- Very thin threads are required for winding micro coils. Generally, the size of the threads varies between 58-61 AWG. As of now, the size of the slimmest secluded thread is 8 microns. These types of micro coils are very much perfect for preparing those medical devices where even a single mm or micron size matters. Devices like catheters, pacemakers, sensors are examples of it.
- Joining two different wires is very important in micro coil winding and this process is known as micro soldering. Traditional soldering processes cannot be applicable for micro winding because of its high sensitivity and precision. The technique used in micro soldering is named as ‘Thermo pressure bonding’.
Preparation of a coil:
A micro coil winding specialist prepares coils through the process of winding isolated wires around a core. In some cases, after the winding is over, engineers remove the core. This process is named as ‘coreless’. Generally, the coils that are coreless, are comparatively smaller in size than other coils, and primarily used in vein insertion. After the mandatory numbers of winding come to 400, 600, 1000, 2000, the thickness of the wires is required to be reduced largely. Reducing the thickness of a wire is a complex task as it needs ultimate expertise, sound technical knowledge, and high accuracy. State-of-the-art tools are needed to evade the isolation breakpoint of the wire. Micro coils are mainly prepared from insulated copper wires as copper is a very good metal for conducting electricity. Though micro coils can be made from other conductors but it mainly depends on the mode of application. Certain coils are bifilar that decreases its inductance power. Bifilar wrapped coils are used in those devices which need more competent fill factor and high sensitivity.
How Micro coils differ from each other:
Micro coils differ from each other by three aspects; material, shape, and size.
- Though copper is used in most coils because of its higher conductivity, other conductors such as titanium, gold, aluminum, silver can also be used.
- The shape of a micro coil mainly depends on the requirement of the device where it will be used.
- Some specific coils are very tiny in size. Normally a tiny, micro coil is much expensive than other non-tiny coils.
Connecting the micro coils:
Coils are a single part of a device and so, it needs to be connected properly to the terminals and the terminals need to be of the same size and thickness. Traditional soldering processes like heat-based soldering, can be difficult as it can damage and cause oxidation to the wires. The process that is safe and used in connecting ultra-fine wires is named as ‘Thermo pressure bonding’.