The procedure of micro-coil manufacturing is not as simple as we think. In addition, it is far more tough and precise than the normal coil manufacturing technique. And the thing that matters most in this process is the size of the coil, which needs to be miniature, in some cases, thinner than our hair.
In this post, we will tell you the custom wire coil manufacturing process and the factors that affect the process. Stay connected and keep reading the post till the end.
How manufacturers make micro-coils:
To make micro coils, manufacturers wind secluded wires around a core. In some cases, they remove the core after completing the winding process. These coils are known as ‘coreless’. Coreless coils are very small in size and used for vein insertion. The higher the number of winding is, the smaller the thickness of the wires becomes. And thus, the most problematic part of coil winding is reducing the thickness of the wires. It requires the ultimate skillset and immense expertise. Moreover, you will also need to super-efficient machines and state-of-the-art technology to eliminate any chance of isolation breakpoint of the wires.
In addition to making the correct micro-coil, it is also important to attach the super-thin wires of the coil with the terminals or with other wires of similar or lower thickness. The traditional heat-based technology is incompetent to do this job, so as the contemporary laser micro-soldering process. These processes can result in heat damage, bad connectivity, oxidation, and many more hazards.
The most effective technology for micro-coil manufacturing is Thermo Pressure Bonding technology. This technology helps in connecting super-tiny wires of any diameter with another wire of the same diameter or near about 12 times thicker.
For instance, in order to fulfill the demand for terminal-base connectivity, you can attach the wires with a gold-plated terminal through Thermo Pressure Bonding technology. Thee molecular connectivity that Thermo Pressure Bonding creates is very much strong, durable, and entirely free from stain and corrosion. Thus, it makes the whole custom wire coil manufacturing process simple and reduces the manufacturing cost.
How micro coils differ from each other:
The main factors that create a difference between micro coils are the material and the shape and size of the coils. Commonly, manufacturers use copper to make micro coils due to their high conductivity and lesser cost. But in some special cases, they also use other metals such as gold, aluminum, silver, titanium, etc.
The size and shape of the coils mainly differ as per the applicational necessity and requirements. For instance, the coils that are used for medical purposes or in body implants, are very small in size. The price of the coils also varies with its size. The smaller a coil is in size, the pricier it becomes due to the requirement of higher expertise to build this.
Final thoughts:
The manufacturing process of micro coils is very delicate and you need to be extra careful in each and every step to remove any chance of any mishap. However, as per the industry experts’ belief, its usage will grow in the near future.
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