The Major Challenges for Electromagnetic Coils Production

Electromagnetic coils are tiny micro-coils that offer electromagnetic properties. The core manufacturing process to produce the electromagnetic coils is the winding process that involves twisting of an ultra-fine wire into a specific shape and size. The material of an ultra-fine wire has to be conductive, for instance, copper. Depending on the requirements of the application area, such as resistance level, inductance level, and desired magnetic field, manufacturers can shape the electromagnetic coil differently, such as round, spiral, rectangular, or helix. Because of the tiny size of the electromagnetic coils, manufacturers use microscopes or magnifying glasses to work with these coils. There are also some major challenges for the production of electromagnetic coils. In this article, we will discuss the electromagnetic coil mechanism, production challenges, and innovative solutions to overcome the challenges.

The Electromagnetic Coil Mechanism:

The purpose of electromagnetic coils is to build interaction between the magnetic field and electrical current and to do that, these coils are essential components of transformers, inductors, sensors, and electromagnets. There are mainly two methods to develop an electromagnetic interaction, such as-

  1. You can apply electric current across the ultra-fine wire and that will help to produce a magnetic field inside the coil.
  2. You can create an external magnetic field in the coil’s interior and that will generate an electric current across the wire. 

Production Challenges:

The electromagnetic micro-coil production process is associated with various challenges in two major areas. Firstly, due to size constraints, manufacturers face multiple challenges, and secondly, traditional connectivity methods are not suitable for the coil winding process.

Challenges Due to Size Constraints:

The electromagnetic coil needs to be produced in a very tiny size so that it can fit into a tiny space of the medical invasive devices or other devices. Typically, the size of an electromagnetic coil should be smaller than the cross-sectional area of a needle. Therefore, to overcome the size constraint and produce miniaturized microscopic parts, manufacturers require innovative micro-motion positioning and control systems. 

Connectivity Challenges:

While ultra-fine wires are necessary for the coil manufacturing process to maintain the tiny size, the main challenge associated with ultra-fine wires is the connectivity issue. Traditional methods for wire connectivity are not applicable for ultra-fine wires as those methods lead to multiple issues. To build effective connectivity between the ultra-fine wires, manufacturers require to apply custom-made methods and machinery.

Thermal Compression Bonding Technology (Connectivity Solution):

To overcome the drawbacks of traditional methods and build an effective joint between tiny wires, manufacturers use thermal compression bonding technology. Thermal compression bonding technology helps to develop corrosion-free, strain-free, and extremely dependable connections. Another major advantage of this method is that you can join two ultra-fine wires of similar diameters as well as different diameters. Even if the materials of the two wires are different, this method is useful. Lastly, manufacturers can use this method efficiently in various environmental conditions. 

Electromagnetic coils are produced through the winding method where ultra-fine wires are twisted around a core in different shapes. Recently manufacturers are also preparing coreless electromagnetic coils by removing the core after the winding process. 


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